Hardfacing is a welding process that adds a wear-resistant layer to metal parts to protect them from wear, stress, and abrasion. The type of metal used depends on the type of wear expected. Hardfacing can reduce maintenance and production costs by extending the life of parts and allowing for repairs.
Facing is a way to protect tools or metal parts from failure due to wear, stress or abrasion. A wear resistant layer is added to the metal by welding thin layers of stronger metals to the surface of weaker metals. Arc welding, oxy-fuel welding or other forms of welding are used to bond the wear resistant layer. The alloys to use for a particular veneering job are chosen based on the underlying material and the type of wear it is expected to encounter.
Sometimes the overlay is applied soon after manufacturing to prevent a tool or part from wearing out over time. It can also be applied to repair a tool or part to working order after wear and tear has occurred. Copper is often used to repair worn parts, while cobalt-based tool steel is used to prevent wear from the start. The type of metal used for the facing also depends on the type of wear and tear to which the metal will be exposed.
Wear can be caused by impact, abrasion, metal-to-metal contact, or a combination of the three. Impact wear occurs when metal is used to crush a hard material, such as stone. Each time metal hits stone, the metal deforms a little more, eventually causing the tool to fail. For example, a sledgehammer could experience impact wear when used to break stone. Manganese alloy is often used as a filler in this case.
Abrasive wear rarely occurs on its own, but is common in combination with impact wear. Abrasive wear occurs when the metal is continually rubbed by dirt or grit. Cobalt facing nickel-based alloys can prevent this problem. Metal-to-metal wear occurs when metal surfaces rub against each other. The metal is gradually worn away or transferred from one surface to another over time. Hardfacing with tool steel can prevent metal-to-metal wear.
Almost any metal can be hardened, but different materials require different types of hardfacing. For example, cast iron must be carefully controlled in temperature to avoid cracking. It also contains carbon, which can interfere with the coating process if the wrong metals are used.
Hardfacing can help reduce both maintenance and production costs. Maintenance costs are reduced because rigid parts are less likely to fail and therefore need to be replaced less often. Also, parts that would otherwise need to be replaced can be repaired using carryover. The cost of production is also reduced because the parts do not have to be made from expensive metal alloys. They can be made from less expensive metals and then hardened for strength.
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