Hardfacing Techniques

Flux‑Cored Arc Welding (FCAW)

FCAW is commonly used for wear‑plate hardfacing. It delivers a high deposition rate, which allows a thick, robust overlay to be built quickly and effectively on large flat surfaces.

Submerged‑Arc Welding (SAW)

SAW is ideal for large wear plates due to its deep penetration and high deposition efficiency. It enables the creation of thick, consistent overlay layers with excellent metallurgical bonding.

Multi‑Pass Overlay Welding

Multiple welding passes are usually applied to achieve the necessary overlay thickness. Careful control of heat input and interpass temperature ensures a uniform hardfacing layer without excessive dilution or cracking.

Controlled Stress‑Relief Cracking

During cooling, micro‑cracks (cross‑check cracks) often form in the overlay. These cracks are not defects but help relieve internal stresses. Proper crack control improves resistance to impact and thermal cycling while preserving surface hardness.

Automated & Precision Welding

The machine supports automated welding modes: linear welding, oscillation welding, and grid welding. This ensures smooth, consistent weld beads and high productivity. A remote control interface displays real-time trolley coordinates, enabling precise control over the welding path.

Hardfacing Materials

Chromium‑Carbide Alloys

Chromium‑carbide alloys are widely used for wear plate applications thanks to their very high hardness and excellent resistance to abrasive wear. The carbide phases in the overlay provide long-lasting protection under severe wear conditions.

High‑Carbon / High‑Chromium Alloys

Wires or electrodes with elevated carbon and chromium content produce dense microstructures. These materials form hard carbides that resist severe abrasion while maintaining sufficient toughness.

Complex Carbide Alloys

For more demanding wear environments, more advanced overlay alloys may include additional carbide-forming elements (such as vanadium or niobium) to increase resistance to erosion, sliding abrasion, and long-term wear.

Layered / Graded Overlays

To improve toughness, a layered approach is often used: a ductile buffer layer is welded first, followed by a hard, carbide-rich surface layer. This improves both impact resistance and wear performance.

Thermal-Stable Alloys

For applications that experience elevated temperatures, specialized alloys can be selected that maintain high hardness even when heated. These overlays ensure long-term stability in high-temperature environments.

Material & Technique Matching Recommendations

For severe abrasion (e.g., chutes, liners, bulk material handling), use thick chromium-carbide overlays deposited via FCAW or SAW.

In areas with impact + abrasion, apply a layered overlay combined with controlled stress-relief cracking to balance toughness and hardness.

When parts are exposed to high temperatures, select thermal-stable overlay alloys to ensure the wear layer retains its hardness.

For large wear plates, use automated welding modes (grid, oscillation) to ensure uniform coverage and efficient deposition.

One button automatic operation

High quality weld deposits

Wireless remote control panel, real-time display of trolley coordinates

Welding wire broken alarm and break point detection

High productivity in manufacturing

10.2 inch colorful touch screen