The process of hardfacing welding has been sought after by many fabrication businesses. But what’s the mysterious success that lies beyond it?
In this complete guide about hardfacing welding, you’ll know and learn everything about it.
Not only will you have the best idea about hard surfacing in welding; you’ll also learn other things that can help you with your business, too!
What is Hardfacing or Hard Surfacing in Welding?
In the simplest terms, hardfacing is the process of depositing hard materials on a surface.
The edges of the bucket are hardfaced to prevent excessive wear because they’re the most used
The goal is to allow a part or a component not to succumb to excessive wear; whether it’s corrosion, abrasion, friction, etc.
Different Hardfacing Welding Electrodes
If you were to perform hard surfacing, you can choose from three (3) categories of electrodes. They are:
This image displays the results of using different hardfacing welding electrodes
Cobalt base electrodes
Iron base electrodes
Nickel base electrodes
Whatever electrode you choose, it’ll undergo alloying with other elements for hardfacing.
Can Hardfacing Welding be Done With MIG Wires?
Yes, you can use Metal Inert Gas (MIG) wires for your hardfacing procedure.
The welder is using MIG wires to prepare the workpiece for MIG hardfacing
In fact, the best MIG wires that experts recommend are: ER70S-6 and ER70S-3. But, your options aren’t just limited to that; you can choose other types and kinds of MIG wires, too!
The point is that you can consider MIG wires to be an electrode that you can utilize for hardfacing.
The video below explains more about how you can perform hardfacing welding using MIG wires.
What Do the Numbers on Hardfacing Welding Rod Mean?
If you’ve been wondering about the meaning of the numbers on welding rods, you’re not alone.
Different welding electrodes with different numbers, meaning different properties
A lot of people aren’t aware of what they are – but they’re actually not something you need to stress on!
These numbers are codes that you can use to identify the specific welding rod.
To start off, there are 4-digit and 5-digit numbers. In a 4-digit electrode number, the first two (2) indicate the tensile strength that the electrode can produce; it’s the first three (3) figures for 5-digit numbers.
The next number, the fourth, and the fifth (for 5-digit numbers), indicate the position of how you should use it.
The number one (1) denotes that it can be used in all positions; two (2) is something you can only use for horizontal and flat welds, etc.
Lastly, the fourth digit (or the 5th in a 5-digit number), tells you about the current welding (DC, AC, or even both), as well as the type of coating that it has.
Ideally, the numbers on a welding electrode helps you understand and identify that particular electrode.
What are Hardfacing Welding Machines?
These are machines that you can use to perform the hardfacing or the hard surfacing you need.
Different hardfacing welding machines Waldun is offering
You have the option to choose from a wide variety of hardfacing welders; there are:
Pipe hardfacing machines and equipment
One-head and two-head hardfacing machines
Robotic and automatic hardfacing machines
Valve hardfacing equipment
Because hard surfacing is a process you can accomplish through different techniques, you can use a lot of machines and equipment for it!
Can Hardfacing be Done With Oxyfuel?
It’s a type of welding process that utilizes oxygen combined with fuel gases for welding.
Process of welding using oxyfuel, which means it’s applicable to hard surfacing
Since it’s one of the most well known and the most prominent welding strategies, you can use it for hard surfacing.
Akin to how you do MIG, SMAW, and PAW hardfacing, you perform oxyfuel welding using a welding torch too!
Here’s a quick clip of how you can use oxyfuel for hard surfacing.
What Materials Can Undergo Hard Surface Welding?
The most common types of base metals or materials that can experience hardfacing include:
Welding chuck clutching on an alloy while being hardfaced
Cast irons and steels
As you noticed, these are materials used by many industrial businesses and companies.
What Welding Techniques Can You Use for Hardfacing Welding?
You can actually perform hard surfacing through various welding methods.
Pipe being hardfaced using traditional Gas Metal Arc Welding (GMAW)
The most common methods you can perform to accomplish it include:
Gas Metal Arc Welding (GMAW)
Submerged Arc Welding (SAW)
Shielded Metal Arc Welding (SMAW)
Plasma Transferred Arc Welding (PTA)
The method you want can’t be just handpicked randomly.
As a matter of fact, the process you’ll have to go with will depend on many things, such as the material you’ll apply over a surface, the type of attachment you want for it, and so on.
Is Hard Surfacing the Same with Hardfacing?
Hardfacing and hard surfacing welding are two (2) similar terms.
Both are known to be processes you can utilize to deposit a new material over a surface. You can think of it as hardfacing being the shorter term for hard surfacing.
Hardfacing Welding vs. Clad Welding
A lot of people know hardfacing in welding to be the same as cladding. However, they’re actually two (2) different processes.
Pipe being cladded with another type of harder material
Cladding or clad welding is a welding overlay process that would yield a new surface. It’s the process of “cladding” or integrating another material on top of an existing one.
Usually, in cladding, you’d use a different material to be cladded to the surface of a workpiece.
Hardfacing or hard surface welding is a process you use to renew or rehabilitate a surface. Unlike cladding, you’ll want a material with almost the same type or the same properties as the workpiece.
That’s how the two processes are different; they’re the same in a sense, but they yield separate results.
How are Cladding and Hard Surface Welding Similar?
Now that you know how they differ, it is also important to know how they became two (2) processes that are similar.
We can summarize this lot by pointing out the following factors:
You can achieve both processes via the following:
Flux-cored arc welding (FCAW)
Plasma transferred arc (PTA) welding
Used by many companies and businesses in various sectors
They have the same end-goal or vision, to protect the part or component or to prolong its lifespan
Both can use a wide range of welding electrodes
What are the Advantages of Hard Surfacing Welding?
Fundamentally, hard surfacing is done because of its benefits and advantages.
The hardfaced edge of the bucket remains completely intact
The most common of these advantages include, but are not limited to:
Prolong the Life of Parts and Components
The primary benefit that hardfacing has is that it can help prolong and lengthen the life of parts. Whether the part is new or worn out, it can give this benefit or advantage.
Eliminate the Need to Replace Parts
If your parts don’t wear out fast, then you immediately eliminate the need to replace them.
Hard surface welding can get you the parts you need stronger, tougher, and more durable.
Increase Productivity and Efficiency
With parts and components good as new, you can be assured that your productivity and efficiency will be increased.
You don’t have to worry or stress about acquiring or sourcing out for parts. Instead, you can focus on your business and your operations.
Save up Costs and Expenses
If we summarize up every advantage it can give us, it’ll come down to you saving money.
With fewer parts needing replacement, less components to purchase, and less work needed done – it all translates to you saving up on extra costs and expenses.
Those are some of the most common benefits you can get from hardfacing welding.
Thee’s nothing spectacular about it; it wouldn’t increase your productivity or give you profits all of a sudden. It is, in fact, a slow but steady addition that you can treat as a big investment.
Hardfacing Welding Rod Types
In hardfacing welding, you don’t have to worry too much on the type of welding rods you’ll use.
A few of the welding rods you can use for hard surfacing
You can choose from the wide variety of options you can utilize. You can use electrodes that have nickel as its base, iron as its base, and cobalt as its base.
Industries That Need to Use Hardfacing Welding
Whether you’re in the construction sector, the industrial sector, fabrication sector, or any other sector you can think of, hardfacing will probably be something you’ll need.
The mining industry needs hardfacing to prolong the life of their machines
A lot of businesses require hardfacing because of the benefits it give. People think that it has something to do with design, but there’s actually more of it than that.
Some of the industries that find hardfacing useful and effective include:
Coal and Mining Industry
Power & Generation Industry
Metal and Metalworking Industry
Shipyard and Shipbuilding Industry
Marine and Maritime Industry
There are other industries that find hard surfacing effective.
Oftentimes, those businesses undergo the usual wear and tear of their machines and equipment.
What Applications Can You Use Hard Surfacing For?
You can use hardfacing for a lot of things. Among the most sought after is its ability to prolong the life of the parts of your machines or equipment.
Apart from that, you can also choose hard surfacing for:
Increasing the resistance of your base or parent metals
Restoring the surface of parts or components that are worn out
Improving or developing the physical traits of parts; and
How Do I Get Rid of Old Hardfacing?
There is a myriad of ways on how you can remove or get rid of old hardfacing. However, the most common and the fastest way is through the ARCAIR system.
ARCAIR, short for Air-Carbon-Arc, is a welding process where the metal is cut and melted. This procedure utilizes a carbon arc and the heat from that arc is what does the job.
More often than not, the molten part is removed and eradicated using high-pressurized air.
This is the fastest and the most reasonable way to remove or get rid of old hardfacing.
Where Can You Find Good Manufacturers of Hardfacing Welding Machines?
The market is filled with a lot of manufacturers and suppliers of hardfacing materials.
But over the years, no manufacturer exceeded the capacity and the skill that the Chinese have.
China’s dominance in the hard surface welding machine industry overtook all other regions in the market.
If you’re not sure where to look for manufacturers, China might just be your best bet.
Which Manufacturer Can You Bank on With Hardfacing Welding?
Here in China, no other manufacturer of hardfacing welding equipment is trusted but us here at Waldun.
For more than a decade, our clients have continually trusted our skills and capabilities. We’re able to produce a wide variety of hard surfacing welding equipment for our clients.
Whether you need a hardfacing machine or you need your parts to be hard surfaced, Waldun is your best bet!
You can ask us to specify the machine you need; or to draw up specifications on the hardface you’re looking for!
Contact us and get the highest quality of hardfacing welding machines you can find!
We offer a free sample of hardfaced materials you need
All your orders will arrive in a maximum of 3 weeks
Waldun has flexible and reasonable payment plans
We can specify your orders to your request!
Don’t hesitate to work with the best! Get the hardfacing service or the hardfacing welding machines you need at a competitive rate!