Tabular Hardfacing Electrodes
A welding engineer involved in repair/reclamation welding, are well aware of low heat input welding consumables and conventionally extruded welding electrodes. These electrodes have found vast "acceptance" by welding engineers in Indian industries. However, low heat input welding consumables, as the name suggests, is a misnomer, when used in relation to conventionally extruded elctrodes. Low heat input is a concept where it is "the technique" which is more important in order to achieve less heat input in the welding components.
» The Technique is:
Using Bare minimum volatge and current.
2.maintaining minimum are gap i.e. the distance between the elctrode tip and the workpiece.
3. Depositing thin layers of stringer welding beads, etc.
These few tips are very important while usingconventionally extruded low heat input electrodes to achieve low heat input which depends mostly on welder skill.
ULTRALLOY Tubular Electrode, a concept well accepted worldwide for hardfacing, "offer hiogh output with least input". These tubular hardfacing electrodes are real low heat input welding products.
» The sailent features of Ultralloy tubular hardfacing electrodes are: -
1. Functions on low operating current, hence low heat input and low dilution.
2. Because of less heat input, the distortion of the component is negligible and therefore no 'burnthrough'.
3. Densely compacted alloy metal constituents within thin steel sheath ensure high deposition rate. The thin layer of slag doesnot call for deslagging betwwen welding runs. (This is unattainable with conventionally extruded electrodes). Hence fast and efficient deposition of hard metal can be achieved.
4. Unlike conventional extruded electrodes, no baking and no special storage is required for ULTRALLOY electrodes.
5. Specially designed electrode stub-end enables easy holding of 6.3, 8 and 10mm dia. electrodes in any electrode holder. the speciaaly designed stub-end also enables ease of use of electrode with pratically no wastage. Like Chromium Carbide clad composite wearplates, the ULTRALLOY tubular electrodes, when manual metal arc welding process is employed, offer excellent wear resistance.
Tabular Hardfacing electrodes have more Techno-Economic benefits than Solid-core Hardfacing electrodes because of:
1. Lower Operating Current.
2. Higher weld metal recovery.
3. Higher deposition rate.
4. Practically no-slag.
5. Non-hygroscopic coating-longer shelf life, no pre-drying.
6. Longer component Life.
Surface Relief checks are normal and in fact desirable on weld deposits having High Carbon - High Chromium, Molybdenum, Niobium, Tungsten, Boron, Vanadium etc. These relief checks occur normally perpendicular to the direction of welding and do not propagate into the base metal.
» Deposition Rate
Size(mm) | Deposition Rate(kg/hr) | |
6.3 | 2-2.5 | |
8.0 | 2.5-3.5 | |
10.0/11.0 | 3.5-5 |
» Weld Metal Recovery
Solid Core 5mm | Tabular 8mm | ||
Wt. of electrode (gms) | 165 | 125 | |
Wt. of weld deposit (gms) | 77.5 | 100 | |
Efficiency/ yield | 77.5/165*100=47% | 100/125*100=80% |
Electrode | Alloy Basis | Hardness | Description | Application | Recomended Current | |
Size | Amps | |||||
UltralloyA W 11 | ( C, Cr ) | Multi Layer 58-61 Rc |
Large Quantities of Chroium Carbide n tough matrix of Austenite. | Bucket lips and teeth, primary coal crushing jaws & hammers, quarry screen plates, blow bar, mentels and liners, gyratory and cone crusher parts etc. | 6.3*400 8.0*450 10.0*450 |
115-140 135-170 175-200 |
UltralloyAw 22 | ( C,Mn Cr ) | As welded 20 to 25 Rc Work hardened upto 50 to 52 Rc | Work Hardening Cr-rich Austentic Deposit. | Railway points and crossings. crusher jaws, crusher hammers, blow bars, toothed crusher rolls, swing hammers, crusher mantles etc. | 6.3*400 8.0*450 10.0*450 |
115-140 135-170 175-200 |
UltralloyA W 33 | (C, Cr, B) | Multi Layer 58-62 Rc | Chronium Carbides & Borides in ahard & fine Martensitic Matrix. | Sand Chutes, dredge components, grizzly bars, screens, scraper blades, bucket lips and teeth etc. | 6.3*400 8,0*450 |
115-140 135-170 |
Ultralloy AW 44 | (C, Cr, MO,Nb,W,V) | Multi Layer 63-67 Rc | Complex Carbides of C, Cr,Mo, Nb, W, V in Austenitic Matrix. | Sinter breakers, sinter fans, clinker wear parts | 6.3*400 8,0*450*10.0*450 |
115-140 135-170 170-225 |
Ultralloy AW 44 Co | (C, Cr, MO, Co) | Multi Layer 60-62 Rc | Complex Carbides in Austenitic Matrix | Blast Furnace bell burden areas, Screen plates, sinter plant breakers, arms etc. | 6.3*400 8.0*450 |
90-130 135-175 |
Ultralloy AW 55 | (W, Cr,C) | Multi Layer 64-66 Rc | Fine tungsten Carbides (52%) Fe-Cr-W Carbides in Martensitic Matrix. | Oil-drill collars, pan scrapers, concrete mixer blades, conveyor screws etc. | 6.3*400 | 95-125 |
Ultralloy AW 55M | (W, Cr,C) | Multi Layer 64-66 Rc | Fine tungsten Carbides (42%) Fe-Cr-W Carbides in Martensitic Matrix. | Oil-drill collars, pan scrapers, concrete mixer blades, conveyor screws etc. | 6.3*400 | 95-125 |
Ultralloy AW 66 | (V, Cr,C,Mo) | Multi Layer 59-63 Rc | Complete Carbides of Cr, Mo, V in tough Austenitic Matrix. | Railway ballast tapmers, dredge buckets and lips, earth moving equipments, power shovels, rolling mill guides, sizing screens, ripper teeth, crushing equipments, bunker funnel, wear plates etc. | 6.3*400 8.0*450 10.0*450 |
115-140 135-170 170-200 |
Ultralloy AW 77 | (Cr,C,Mn,Ni) | Multi Layer 52-58 Rc | Chronium Carbides in Austentic Deposit. | Grey cast iron components, brick pan tyres and pathways, shovel buckets,crusher rolls and rock shackles. | 6.3*400 8.0*450 10.0*450 |
115-140 135-170 175-200 |
Ultralloy AW 88 | (Cr,C,Mo,Ni,V) | Multi Layer 57-60 Rc | Complex Carbides of cr, mo,V in tough Austenitic Matrix. No refer checks. | Bunker funnel, try ash conveyors, tongs, crusher hammers etc. | 6.3*400 8.0*450 |
115-145 135-170 |
Ultralloy AW 99 | (C,Mn,Cr,Ni) | As welded 18 to 20Rc. Work hardened upto 48 to50 Rc. | Austentic Manganese steel deposit with essential addition of Ni & Cr. | Buffer layers before hardfacing worn out components of manganeses steels. | 6.3*400 8.0*450 10.0*450 |
115-135 135-170 170-200 |
Ultralloy AW 16-0 | (Cr,C,Nb, Mo) | Multi Layer 55-60 Rc | Large quantities of Cr & Nb carbides in tough and hard Austenitic Matrix. | Quarry swing hammers, pulveriser hammers | 6.3*400 8.0*450 10.0*450 |
80-130 130-180 180-220 |
Ultralloy AW 14-0 | (Cr,C,Nb,W,Co) | Multi Layer 52-54 Rc | Tool Steel | Hot Shear blades, lifting tongs of bilets, tools for hot die forging, tools for hot punching. | 6.3*400 8.0*450 |
110-140 135-170 |
Ultralloy AW 18-0 | (Cr,C,Ni,Mo) | 52-56 Rc | Appreciate quantities of Chronium Carbides in a tough Austenitic Matrix. | Valve seats, crusher parts employed in chemical and mining industries. | 6.3*400 8.0*450 |
115-140 135-170 |
Ultralloy AW 28-0 | (Cr,C,Ni,Mo) | NA | Excellent high strength, Austeno - Ferretic Stainless Steel Tubular Electrode. | Joining Machinable build up and overlay | 6.3*400 | 80-140 |
Ultralloy AW 117-0 | (fe,Cr,Ni,Mo) |
1) As deposited 45-50 RC 2) After tempering at 550-600 deg C-40-45 RC |
Weld metal comprises of Martensite and fairly dispersed retained Austenite. | Reclamation of forging dies, connecting rods, crank -shaft,axlebearing, suspension components, hot shear blades, roll face repairs lifting tongs for billets, tools for hot trimming and cold punching of dies and tools etc. | 6.3*400 | 90-160 |
Ultralloy AW 50-0 | (C,Cr) | Multi Layer 47 to 52 RC | Weld metal contains appreciable quantities of chronium carbides in tough matrix of Austenite. | Shaft, Conveyor Screws, Wire - drawing Drums, Wear - resistant build -up which requires machining. | 6.3*400 8.0*450 10.0*450 |
75-130 110-160 130-180 |
Ultralloy AW - CI | (E Fe - Ni) | Na | A tabular electrode with special flux having no barium compounds. | Repair of machine framers, bases, pump bodies, Engine blocks, Bearing blocks, gears and pulleys, Foundry defects, Transmission housing etc. | 6.3*450 | 75-130 |
Ultralloy AW - CI-O | (Ni,Fe, Mn-C) | Na | A tabular electrode with special flux having no barium compounds. | Repair of machine framers, bases, pump bodies, Engine blocks, Bearing blocks, gears and pulleys, Foundry defects, Transmission housing etc. | 6.3*450 | 75-130 |
Zugar C | (C,Cr, V, Ni) | 58 to 61 RC | First time a technological breakthrough - a touch type tabular electrode for hardfacing of sugarcane crusher rolls in Situ &juice on conditions. | Sugarcane Crushing Rools. | 6.3*400 | 120-150 |
Zugar H | (C,Cr,Mo,V, Ni) | Multi Layer 58 to 61 RC | Comprises of Complex Carbides in Austenitic Matrix. | Sugarcane Cutting Knives. | 6.3*400 8.0*450 |
115-140 135-170 |
Zugar K | (C,Cr,Mo,V, Ni) | Multi Layer 57 to 60 RC | Comprises of Complex Carbides Cr, Mo & V in tough Austenitic Matrix. | Fiberiser Hammers and shredded hammers. | 6.3*400 8.0*450 |
115-140 135-170 |
Durapaste is a highly abrasion resistant alloy of Chronium-Moly-Carbon-Boron designed, developed and manufactured indigenously by Duraweld, Durapaste offers strengthened, improved martensitic micro structure which helps improve matrix toughness and prevents the tearing-out of carbides by hard/sharp particles.
• It can be used effectively in the applications involving temperatures upto 350 degree C.
• Maximum hard layer deposit of 1.5mm can be obtained with Durapaste.
• Durapaste has martensitic (needle like) microstructure, therefore hard abrasive flying dust doesnot penetrate the hard deposit.
• Matrix Hardness 750-825 HVN
• One kilogram of durapaste can cover an area of 0.25 to 0.3M.
• Durapaste can be applied on any ferrous material surface where carbon equivalent is less than 0.3%.