Cladding Consumables and solutions

Welding rods used for TIG welding are also used for hardfacing with the oxy-acetylene welding process. With the correct operation, a very low level of iron dilution can be achieved in the overlay.

Rod is available in these standard diameters:

• 2,6 mm (3 / 32") (special order)
• 3,2 mm (1 / 8")
• 4,0 mm (5 / 32")
• 5,0 mm (3 / 16")
• 6,4 mm (1 / 4")
• 8,0 mm (5 / 16")

These diameters are not available for any alloys. Special sizes on request.

MMA welding is still a widely used hardfacing process. In this process, an arc is drawn between a coated consumable electrode and the workpiece. The metallic core is melted by the arc and is transferred to the weld pool as molten droplets.

Electrodes are available in these standard diameters:

• 2,6 mm (3/32") (special order)
• 3,2 mm (1/8")
• 4,0 mm (5/32")
• 5,0 mm (3/16")
• 6,4 mm (1/4")

Electrodes are supplied in lengths of 350 mm (14”) and are boxed in 5.0 kg (11 lb) boxes.

In these arc welding processes, consumable hardfacing wire is fed continuously from a spool through the welding torch into the arc, where it is melted and transferred to the workpiece. Wire is also used as the hardfacing consumable in the Submerged Arc Welding (SAW) process. In this process, a mineral-based fluxing powder flows around the consumable wire and is melted by the arc.

Electrodes are available in these standard diameters:

• 1,2mm (0.045") — supplied in 15 kg (33 lb) spools
• 1,6mm (0.062") — supplied in 15 kg (33 lb) spools
• 2,4mm (0.093") — typically supplied in 25 kg (55 lb) spools
                                    (optionally in 15 kg spools)
• 3,2mm (0.126") (special order) — supplied in 15 kg (33 lb) spools

A specially-designed oxy-acetylene torch is used for powder welding. The workpiece is heated with the torch, powder is introduced into the gas stream from the integral powder hopper and transferred to the workpiece through the flame.

Powder Welding powders are available in these standard size ranges:

• KS 20–63 μm
• KX 20–106 μm
• K 20–75 μm

The PTA process is easily automated, providing a high degree of reproducibility of the weld overlays. Because the hardfacing materials are in powder form, it is possible to produce overlays from many different materials and combinations of materials with a wide range of hardnesses and other properties.

PTA hardfacing powders are available in these standard powder particle size ranges and custom sizes upon request.

• WM53 –180μm
• WE 63 –180μm
• E 53–150μm
• G 38 –125μm
• HK 63–210μm
• W 63 –150μm

When overlaying with a laser, an optical arrangement is used to focus the laser beam on the workpiece and heat it. Simultaneously, hardfacing material in the form of powder or wire is introduced into the laser beam and melted.

LASER hardfacing powders are available in these standard powder particle size ranges and custom sizes upon request.

• WM53 –180μm
• WE 63 –180μm
• E 53–150μm
• G 38 –125μm
• HK 63–210μm
• W 63 –150μm

Additive Manufacturing of metallic parts based on a powder-bed technology, such as Selective Laser Melting, Electron Beam Melting or Binder Jet Method, require special specification of the powder used for the processes.

• Our standards cuts AM applications are 45/10 μm and 38/10 μm
• Customized chemistries and grain size distributions are possible on special request