In heavy industries, equipment often experiences extreme conditions, so durability and longevity are required. Constant wear and tear can cause operational challenges and increase maintenance costs. To tackle these problems, hardfacing, a technique that deposits layers of extremely hard materials onto the surfaces of components, is created and used to improve their resistance to impact, abrasion, and corrosion. Hardfacing consumables are a crucial part of the hardfacing process. They are often in the form of welding rods, composite rods, wires, or powders. Today, we will uncover different types of hardfacing consumables available.

1. Hardfacing powders

Hardfacing powders are typically composed of a mixture of metallic powders that are welded or sprayed onto the surface of a workpiece to extend its service life. Hardfacing powders are used in the thermal spray (HVOF, LVOF, plasma, or cold spray) process. Common types of hardfacing powders include tungsten carbide, chromium carbide, stellite, nickel-based alloys, and iron-based alloys.

2. Hardfacing rods or electrodes

Hardfacing rods or electrodes are designed to be deposited on the surface of a metal component to form a wear-resistant layer. These rods consist of a core wire and a flux coating. The purposes of the flux coating are shielding, arc stability, and slag formation. Hardfacing rods or electrodes are applied in the SMAW, FCAW, GMAW, GTAW, and more processes.

3. Hardfacing wires

Hardfacing wires are commonly used in MIG welding. This type of hardfacing consumable can offer an excellent level of wear resistance. Compared to hardfacing stick rods or electrodes, wires are more efficient to apply.

4. Tungsten carbide composite rods

Tungsten carbide composite rods have two main purposes: enhancing wear resistance and cutting. They comprise a high tensile matrix alloy and tungsten carbide particles or inserts. Composite rods are commonly used in the oil and gas, mining, construction, and geological exploration industries.

5. Tungsten carbide pellets

Tungsten carbide pellets are small spherical particles composed of tungsten carbide and the cobalt binder. They are commonly used in hardfacing processes to extend the service life of components. Common applications of carbide pellets include construction spare parts, drilling tools, plowshares, valve seats, and wear plates. Thanks to tungsten carbide, these pellets can provide outstanding wear resistance and hardness.

KoneCarbide supplies a wide range of hardfacing consumables, including tungsten carbide composite rods, crushed grits, and tungsten carbide inserts for stabilizer gauge protection. Our salespeople are ready to help in providing tailor-made hardfacing solutions to minimize downtime and enhance productivity.