How to Speed Up Equipment Repairs with Hardfacing Techniques

In high-wear industries like mining, cement, steel, and thermal power, every hour of equipment downtime can mean serious production and revenue loss. Hardfacing is a proven solution to repair and reinforce worn parts, but it’s not just about welding—it’s about efficiency, preparation, and using the right materials.

Based on years of industry service and feedback from customers worldwide, here are 7 actionable tips to make your hardfacing repairs faster and smarter—with JH Hardfacing’s products at the center of each step.

Use Ready-to-Weld Flux-Cored Hardfacing Wire to Save Time

JH Hardfacing offers flux-cored hardfacing wires (e.g. JH-HF60, JH-HF65) with high deposition efficiency—up to 8kg/hour—perfect for fast repair of large surfaces.

• Wire size: 2.8mm / 3.2mm

• Hardness after welding: HRC 58–65

• Ideal for: Crushers, mixer blades, bucket edges, screw conveyors

• Bonus: Open arc welding eliminates the need for gas shielding

Tip: Use automated or semi-automatic surfacing to boost coverage rate and reduce fatigue. With JH wire, many customers report 30–50% reduction in weld time compared to stick electrodes.

Reduce Downtime with Prefabricated Chromium Carbide Overlay (CCO) Plates

Instead of building up worn areas on-site, use pre-welded JH wear plates, cut and drilled to shape in advance:

• Overlay thickness: 3–20mm

• Hardness: HRC 60 ±2

• Service life: Up to 5–10x longer than NM400 or AR500

• Cutting options: Plasma, waterjet, laser

• Available as: Flat plates, curved segments, welded assemblies

Application Examples:

• Clinker chute liners (cement plant): Pre-cut and bolted in under 1 hour

• Crusher screen plates (quarry): Lasting 6–8 months per cycle

• Cyclone inlets (steel plant): Preformed into cones, delivered ready to install

Tip: Send your part drawings to JH Hardfacing for fast laser-cut solutions and edge-beveled holes.

Speed Up Rebuilding with Pre-Coated Wear-Resistant Pipes and Elbows

For pneumatic and slurry systems, JH’s inner-lined hardfacing pipes drastically reduce on-site repair work:

• Inner wear layer: Chromium carbide overlay (HRC 58–62)

• Outer wall: Seamless or welded steel

• Sizes: DN80–DN500, customized lengths and bends

• Applications: Ash handling pipes, cement dust transport, mineral slurry delivery

Compared to ceramic-lined pipes, JH wear pipes offer better welding adaptability, lower risk of cracking, and faster replacement during shutdowns.

Tip: Stock spare elbows in high-wear zones to minimize pipeline repair windows.

Avoid Over-Welding

Using the wrong alloy costs time and risks failure. JH Hardfacing provides multiple formulations:

• JH-HF60: Best for sliding wear

• JH-HF65 Complex Alloy: Ideal for mixed abrasion + moderate impact

• JH-HF50: Suitable for high impact and low abrasion (crusher applications)

Application Matching Table:

Control Layer Thickness and Flatness

JH Hardfacing’s automated surfacing process ensures:

• Overlay flatness tolerance: ≤3mm/m

• Thickness tolerance: ±0.5mm

• Layer uniformity: Reduces post-weld machining

• Low dilution zone: Preserves alloy performance

Customer Case: In a coal-fired power plant, switching to JH plates with consistent flatness reduced post-installation grinding from 5 hours to just 45 minutes per liner set.

Plan Your Pass Sequence and Cooling Time

To avoid cracking and ensure fast, effective repair:

• Use 2–3 layers max for field repair

• Keep interpass temperature below 300°C

• Allow passive cooling between passes

• Avoid water cooling—thermal shock risk

Tip: Weld horizontal surfaces first to simplify positioning and reduce rework time.

Keep Critical Spares Stocked for Fast Change-Out

Many customers reduce unplanned downtime by keeping ready-to-install JH parts on site:

• CCO liner kits

• Pre-cut fan blades and cyclone bodies

• Lined pipe elbows and T-joints

• Hardfacing wires for field repair kits

JH supports bulk orders of standard shapes with quick delivery and cut-to-fit options.

Conclusion

Hardfacing can restore your equipment—but smart planning and the right material selection will make your repair process faster, more consistent, and more cost-effective. Whether you're rebuilding worn surfaces or fabricating new wear zones, JH Hardfacing’s full line of wear-resistant products is designed to help you work faster and last longer.