PRESENT INTERNATIONAL STATUS OF TUBULAR ELECTRODES FOR HARDFACING APPLICATIONS

ADOR FONTECH LIMITED

Hardness Vs. Wear (cont)

A Micro Hardness test on the other hand measures the individual hardness of each grain or particle. Although, macro hardness indicates resistance to wear, but the actual micro-hardness of the hard particles in the the matrix of hardfacing material which imparts such high average macro-hardness is the important criteria for determining wear resistant properties. This knowledge eventually helps to select most suitable alloy for a specific type of WEAR.

Universal recognition of nature of alloying elements & its total contents (approx) in Weld-Metal for best WEAR RESISTANCE
Alloying elements & its total content (approx) in %age
C,W,Cr 65 C,Cr,B,Mo,V 34 C,Cr,Mo,Nb,W,V - 54 Mn,Cr 30 C,Cr,Nb,Mo- 38 C,Cr,Mo,Ni- 37 C,Cr- 40 C,Cr,Mo,Ni - 35

Abrasion

Erosion

High Temp Abration

Impact

Corro sion

Friction

9 7 7 4 8

5 9 7 2 7

5 4 9 2 5

3 3 4 9 7

3 4 3 4 3

8 4 4 2 5

7
6 5

7
6 4

6
6 4

7
6 4

3
3 8

2
2 4

Maximum 10 points allotted in each type of WEAR RESISTANCE

CONCEPT OF TUBULAR ELECTRODE

The advent of Solid-Core electrode for joining took place about 100 years ago.Then, came Solid-Core electrode for Hardfacing where such high alloy contents in the weld-metal were the primary conditions to impart wearresistant surfaces on base metal.

Since high alloying elements need to be transferred across the arc to the weld-metal, thick flux coatings for such Hardfacing Solid-core Electrodes became the necessity. As a result of such thick flux coating the characteristics like
i) high operating current ii) high slag volume iii) spatter etc were associated with such Solid- Core Hardfacing electrodes.

To get over such difficulties of operations the concept of making of highalloys containing electrodes through Powder-metallurgical method came to the minds of Developers which has finally given rise to the present form of Tubular Hardfacing Electrodes.

Constructional Features of Tubular Electrode lead to:Low operating current Low heat-input Less distortion No burn-through Hardfacing on thin sections Low dilution Uniform alloy distribution Weld deposit richer in carbides No deslagging No special storage Universal grip for all sizes High deposition rate Un-limited shelf life No pre-drying High recovery

Dilution
Solid-core (4.0mm) Operating Current 140 amps Tubular (6.3mm) Operating Current 85 amps

High 35 40%

Low 10 to 15%

Spatter loss- high Slag Volume high Slag removal-essential Recovery: 47 -55%

Spatter loss- nil

Slag negligible Deslagging-not required Recovery: 80 85%

Deposition Efficiency 55%

Kg of electrode required 1.82

Deposition Efficiency 85%

Kg of electrode required 1.18

Electrode Savings 35% approx.

Shortcomings of THF electrodes in Earlier Years

1. Open Arc.
2. Restricted to Down hand & Horizontal welding (Limitation in Positional Welding). 3. Restriction of Size. (non-availability below 6.3 mm). 4. Limitation to manufacture low alloy

Developments in the International Scenario to Overcome Shortcomings

1.Available with almost identical arc characteristics of solid core
electrode i.e close arc and touch types. 2.Vertical and Overhead position welding in certain type of THF Electrodes are claimed today by few Manufacturers. 3.Minimum size of 5.0mm available. 4.Low alloy (containing 12-16%) giving martensitic / austenitic microstructure are available. 5. Besides Hardfacing, Joining type THF Electrodes for Cold Welding of Cast iron are now available conforming to ENiFe-CI and ENiFeMn-CI. These varities of THF Electrodes also enjoy the Economic Advantages in comparison to equivalent Solid-core Electrodes.

Conclusions
It is heartening to note that the Indian Industries are now taking advantage of these Techno-Economic benefits of Tubular Electrodes and are at present using these electrodes on larger scale since the earlier shortcomings were overcome. Thereby, the Industries demand of THF electrodes is felt by the Electrode manufacturers in the country today. Hence, the established manufacturers of Solid-core hardfacing electrodes are now either Manufacturing or Importing THF electrodes to cater to the demands of these Industries.
From our experience we find that the demand of these products in the International Market is growing day by day. It is an universally accepted fact that THF electrodes give greater wear resistance & twice the value for Money of Solid-Core Hardfacing Electrodes.