What is Hardfacing?

In the world of metalworking, you would almost always encounter or hear hardfacing.

Many people have the slightest idea on what it is, while there are others that don’t! In today’s guide, we will be focusing on discussing everything you need to know about hardfacing.

At the end of this guide, you will definitely be able to wrap your head around it! Let alone, be a master of what it is!

Defining What Hardfacing Is

In simple terms, hard surfacing or “hardfacing,” is a metalworking procedure where you deposit tougher and harder material to a surface of a base metal.

Defining What Hardfacing Is
An example of a hardfaced excavator bucket

The primary purposes of hardfacing are for the general improvement of the base metal.

You can perform hardfacing if:

  • You want to prolong the lifespan of your parts and/or components
  • Your parts are already worn-out, to restore them
  • You’re looking to improve the performance of whatever part you have
  • You want to apply a wear-resistant material to your surface

Hard Facing Welding Rod in Hardfacing

A welding rod is an electrode; and what this means is that it’s what you deposit to the surface of your base metal.

Hardfacing Welding Rod In Hardfacing
Hardfacing electrodes or welding rods

Without a hardfacing welding rod, you wouldn’t be able to apply or deposit a tougher, stronger, and a more durable material.

You can choose from a wide variety of hardfacing welding rods available in the market; it’s not just limited to one (1) kind.

What are the Advantages of Hardfacing?

Why should you perform hardfacing? Does it give you any benefit or advantage at all?

What Are The Advantages Of Hardfacing
A damaged chute because it doesn’t have hardfacing

We’ve gathered some of the most sought after advantages you can have in performing hardfacing:

Decreased Downtime Instances

Adding up an extra layer of protection to your parts and components can help it become durable. Thus, reducing the instances of breakage, damage, and downtime.

This is one of the many reasons why a lot of people go with hardfacing.

Longer Lasting and More Durable Parts and Components

What’s the most common reason why some base metals get worn out? – Because of having little-to-no protection.

With hardfacing, you not only get extra protection; your parts can also become abrasion and corrosion-resistant, too, making them last longer and become more durable.

Reduced Costs

A significant reduction in cost is one of the most notable benefits of hardfacing.

Because of the fact that it allows base metals to be stronger, tougher, and more durable, you will have fewer needs to repair and replace them – giving you relevant reduction in cost.

Better Part Performance

Imagine a chute without any type of hardfacing – do you think they’ll function properly?

They absolutely will, for a time. However, if you continue to use it without any sort of protection, it’ll be damaged – and not for long, it can break.

If it has a hardfacing coating, you can expect it not to wear down easily. Making it function better and more efficiently.

Reduced Storage Space Needs

Hardfacing protects your parts and components to be worn out; reducing the need for you to store spare and back-up resources.

In asking what hardfacing is, these benefits can clearly give you the answers you’re looking for.

To let you know, though, these aren’t the only advantages you can get with hardfacing, there are a lot more!

But, the endpoint of these benefits and advantages would fall on you gaining more savings and reducing costs!

Thermal Spraying vs. Hardfacing: How Do They Differ?

Hardfacing and thermal spraying aren’t two (2) fruits from a different tree.

Thermal Spraying Vs. Hardfacing
Thermal spraying procedure in hardfacing a round workpiece

As a matter of fact, thermal spraying is one of the processes used in hardfacing. Hardfacing is the more general term of material deposition over a base metal.

Thermal spraying is a kind of hardfacing technique where droplets of semi-molten material are deposited, creating the coating or the hardface.

The Most Common Materials Used in Hardfacing

Now that we’re aware of the fact that hardfacing utilizes tougher and stronger material, what are the most common ones you can use for it?

Most Comon Materials Used In Hardfacin
Nickel-based alloys – one of the most common materials used in hardfacing

The most common materials you can apply in a hardfacing procedure includes:

  • Nickel-based alloys
  • Chromium carbide alloys
  • Stellite
  • Cobalt-based alloys
  • NOREM Alloy

What is NOREM?

If you got confused with what NOREM is, don’t worry – you’re not alone.

NOREM is known as a hardfacing material developed by the Electric Power Research Institute or the EPRI.

It’s a cobalt-type hardfacing alloy that is wear resistant and is known to have replaced other cobalt-based.

You can find NOREM in nuclear and chemical industries, and sectors of those sorts.

As of today, there are a total of eight (8) variants of NOREM, namely:

  • 02
  • 02A
  • 03A
  • 03B
  • 04A
  • 04B
  • 05A
  • 05B

Methods Used to Deposit Hardfacing

There are quite a few techniques and processes you can perform to deposit hardfacing.

Methods Used To Deposit Hardfacing
A construction machinery part hardfaced using laser cladding

Some of the most common welding processes include:

  • Shielded Metal Arc Welding (SMAW)
  • Oxy-Fuel Welding (OFW)
  • Electro Slag Welding (ESW)
  • Submerged Arc Welding (SAW)
  • Plasma Transferred Arc Welding (PTAW) or Powder Plasma Welding
  • Gas Metal Arc Welding (GMAW)

Apart from welding procedures, you can also perform other techniques, which are:

  • Laser Cladding
  • Thermal Spraying
  • Cold Polymer Compounds
  • Hard Paint

The goal is to be able to deposit the material onto the surface, so any of these processes is good.

Do You Need to Heat Workpieces Before Hardfacing Them?

One of the general rules of hardfacing is that all workpieces must be brought to room temp.

Do You Need To Heat Workpieces Before Hardfacing Them
Semi-molten material being used for hardfacing

However, it’s not something you should abide by 100% of the time.

In fact, some metals and alloys are required to be preheated before working on them; this will depend on the chemical composition of that alloy or metal.

Is Hardfacing Limited to Just One (1) Layer?

No, hardfacing can even go up to two (2) to five (5) layers, depending on the product.

Is Hardfacing Limited To One Layer
Multiple-layer hardfacing on a heavy-earth moving equipment

Products that are a part of metal carbide families are just limited to just 2 to 3 layers. On the other hand, though, you can apply an unlimited amount of layers if you use austenitic and martensitic products.

Machines Used for Hardfacing 

Hardfacing isn’t a procedure you can do without any machines or equipment.

Machines Used For Hardfacing
One-head hardfacing machine offered by Waldun

In fact, choosing the right machinery will get the job done easier, faster, and more conveniently. The machines you’ll choose will depend on the results you want to achieve.

Nevertheless, here are some examples of machines you can use for hardfacing:

One and Two-Head Hardfacing Machine 

It’s a type of machine where a welding head is present. The one-head contains one (1) welding head, while the two-head has two (2).

Furthermore, it has a bed where the workpiece shall be loaded.

It’s a good type of machine because it reduces workforce while ensuring the quality of the hardfacing procedure.

PTA or Plasma Transferred Arc Welding Machine 

PTA welding equipment is a sort of thermal process where AR material is applied and deposited to surfaces.

Compared to others, they’re considered to be flexible and versatile machines.

Pipe Hardfacing Equipment

Working on pipes is not the same as working on a flat-shaped workpiece.

Pipes and tubes need a specific type of machine in order to get the work done – that’s what pipe hardfacing machines are for.

It utilizes automatic arc welding and is multifunctional.

These aren’t the only machines you can use to perform hardfacing – there are others, in fact, a lot more! These are just equipment widely and most commonly used.

Can You Perform Hardfacing on Excavator Buckets?

Hardfacing has a significant impact in both heavy-earth and construction industries.

An Excavator Bucket Hardfaced With Durable And Tough Material
An excavator bucket hardfaced with durable and tough material

Therefore, performing hardfacing on excavator buckets can yield a lot of positive results, in terms of strength, durability, efficiency, and effectiveness.

Hardfacing Electrode Price

Without an electrode, you wouldn’t be able to perform hardfacing.

So, the million-dollar question is, how much do they cost? To be frank, hardfacing electrodes and rods differ in prices.

More so, their prices would depend on a lot of factors, including:

  • The element of the hardfacing electrode
  • Tensile strength and hardness
  • Composition

What Types of Wear Can Hardfacing Put an End To?

Depending on your industry and the use of your parts and components, hardfacing can stop many different types of wear.

What Types Of Wear Can Hardfacing Put An End To
Damaged pipe because it lacks hardfacing

The most common ones include abrasion, corrosion, impact, friction, and heat. By performing hardfacing, you wouldn’t have to worry about these types of wear!

Is Cracking on Hardfaced Alloys Normal?

Cracking is a sign of inconsistency and breakage – therefore, it’s not normal if you look at it generally.

Is Cracking On Hardfaced Alloys Normal
Cracking on hardfaced alloy

However, there are types and instances where cracking is part of its natural physicality.

For instance, chromium carbide alloys show check cracks whenever they’re cooled down to median temperatures; and in this case, it’s normal.

But, you always need to see cracking as a type of hint going to damage or breakage.

Can You Perform Hardfacing on New Parts?

Absolutely! As a matter of fact, most companies make this choice in order for the parts to have a longer lifespan, and to be able to function better and properly.

The increased wear resistance that it has offers a domino effect on all other benefits.

All of the advantages and benefits of hardfacing would also apply if you perform hardfacing on newly manufactured and produced parts and components.

Who Can You Trust With Hardfacing and Hardfacing Machines?

The industry is filled with a lot of hardfacing machine and equipment manufacturers.

But, working with the best one you can find in the market will definitely give you a boost! Which hardfacing machine supplier can you trust?

Here in the country, only us here at Waldun are trusted when it comes to hardfacing.

Whether you need hardfacing performed, or if you need hardfacing equipment, you can bank and count on us!

Why Work With Waldun For Your Hardfacing Needs?

Waldun has been the face of hardfacing and welding for the past 15 years.

Why Trust Waldun
Waldun is your number one hardfacing machine manufacturer – we’re the best!

We’ve proven our skill and our overall competence in the industry by providing custom hardfacing machines and equipment to our clientele.

Waldun’s line of hardfacing machines and equipment are complete – we have valve hardfacing machines, pipe hardfacing machines, to one and two-head hardfacing equipment!

  • We have an virtual showroom where we can showcase the machines we have
  • Waldun has a competent Research & Development (R&D) team to help you with whatever you need
  • All our machines have a one (1) year, clean warranty for any defects
  • We are ISO 9001 and ISO 14001 certified
  • We have a highly-responsive customer service team

Waldun’s Competitive Advantages With Hardfacing Machines

Being in the business for more than a decade, we have mastered every process there is. From manufacturing hardfacing machines, to providing hardfacing solutions to businesses that need it – you can count on us!

Add the fact that we employ the best, the most skilled, and the most talented engineers and tech experts, you will never regret your decision of choosing us!

Unlike other manufacturers, we don’t just focus on one (1) type of hardfacing equipment – we offer a vast array of options, and you can customize the machines and how you want it, too!

If you choose us, you’ll never fall short of the hardfacing machines you’ve always wanted.

Contact us by sending us an email about the products you need! We will be more than glad to give you a free quotation!

Get the hardfacing machines you need at the lowest and the most discounted rates, without compromising the quality!

Get A Quote Now !