Hardfacing Techniques

Flux‑Cored Arc Welding (FCAW)

FCAW is widely used for overlay hardfacing on vertical roller mill rollers. It provides a high deposition rate, allowing thick, dense overlays to be deposited quickly. This efficiency is particularly beneficial when restoring or building up the surface of grinding rollers or tables in a vertical mill.

Multi‑Pass Weld Overlay

Multiple welding passes are often required to build up adequate overlay thickness. Skilled control of heat input is essential during each pass to ensure uniform distribution of the hard phase and to avoid excessive dilution that could weaken the hardfacing layer.

Controlled Crack / Stress‑Relief Patterning

As the overlay cools, micro-cracks naturally form. Properly controlled crack spacing helps relieve internal stresses, offering enhanced resistance to impact while maintaining hardness. This is especially important for high-stress mill environments.

On‑Site / In‑Place Hardfacing

For vertical roller mills, on-site hardfacing (welding directly on rollers or tables) can be performed. This avoids full disassembly, shortens downtime, and allows for rapid refurbishment. Welding parameters and consumables should be selected to minimize distortion and ensure a strong metallurgical bond.

Grinding Table Rebuild

In addition to rollers, the grinding table of a vertical mill is another critical wear zone. The table can be resurfaced with hardfacing overlay, restoring worn areas to original or improved wear resistance standards.

Hardfacing Materials

Chromium‑Carbide Alloys

Chromium‑carbide overlays are commonly used for vertical mill components. These alloys contain hard carbide phases, providing excellent abrasion resistance under mill operating conditions.

High‑Carbon / High‑Chromium Alloys

Electrodes or wires with high carbon and chromium content are used to form dense, high-hardness microstructures. These materials form carbides that resist severe abrasion and wear.

Stress‑Relief Alloy Layers

To reduce the risk of overlay cracking under heavy load, a graded overlay can be applied: a lower-alloy (more ductile) layer near the base, followed by a high-carbide, high-hardness outer layer. This layered approach balances toughness and wear resistance.

Material & Technique Matching for Vertical Roller Mills

For roller surfaces under extreme abrasion, a thick chromium-carbide overlay using FCAW or multi-pass welding is highly effective.

If the mill experiences impact plus abrasion, controlled crack patterning helps absorb strain while preserving hardness.

For grinding tables, resurfacing with chromium-carbide overlays restores worn geometry and extends service life.

During on-site refurbishment, welding parameters and material selection should minimize distortion, ensuring rollers and tables remain within tolerances.

Key Benefits

Longer Component Life — Hard, wear-resistant overlays significantly reduce material loss on rollers and tables.

Reduced Downtime — On-site overlay welding allows refurbishment without complete disassembly.

Cost Efficiency — Restoring worn parts with hardfacing is generally more economical than full replacement.

Reliable Performance — Controlled microstructures and crack patterns balance hardness and toughness, even under heavy load.

Hardfacing machine manufacturer

JINHUA, founded in 1996, is a global leader in the innovation and production of hardfacing wire and wear-resistant welding equipment. With over 20 years of experience, JINHUA specializes in providing complete welding automation solutions tailored to various industries, including mining, agriculture, recycling, and construction. Partnering with TELF AG and utilizing top-grade FeCrHC from Kazakhstan, JINHUA delivers superior quality hardfacing consumables. Certified to ISO 9001 standards, JINHUA is committed to offering reliable, high-quality products that exceed industry expectations across sectors such as petroleum, automotive, and aerospace.

At JINHUA, we use only the highest quality materials and components in our machines, ensuring that they are built to last and can withstand even the toughest working conditions. We produce different types of hardfacing machines for different applications, including: pipes, plates, rolls for rolling steel, etc. We'd be happy to share their parameters or pictures, as well as videos of their work!

We take pride in our commitment to innovation and customer satisfaction, and our team of experienced engineers and technicians works closely with each customer to provide customized solutions that meet their unique needs and requirements. With our comprehensive after-sales support and maintenance services, you can trust that your JINHUA hardfacing cladding machine will continue to perform at its best for years to come.

Choose JINHUA for your hardfacing cladding machine needs and experience the quality, reliability, and performance that our customers have come to expect.

One machine with two function, air carbon gouging and hardfacing welding.

Automatic circular welding, oscillation welding, linear welding, diamond pattern automatic welding

In situ application for minimum downtime

PID closed-loop operation

Chromium pick copper open arc surfacing welding torch, can work continuously for 24 hours