Abrasion resistance of GMA metal cored wires surfaced deposits
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Journal of Materials Processing Technology164–165(2005)1056–1061Abrasion resistance of GMA metal cored wires surfaced depositsA.Klimpel a,∗,L.A.Dobrza´n ski b,D.Janicki a,A.Lisiecki aa Welding Department,Silesian University of Technology,ul.Konarskiego18A,44-100Gliwice,Polandb Division of Materials Processing Technology and Computer Techniques in Materials Science,Institute of Engineering Materials and Biomaterials,Silesian University of Technology,ul.Konarskiego18A,44-100Gliwice,PolandAbstractA study was undertaken of four iron and two cobalt based hard facing alloys as GMA cored wire surfaced to evaluate quantitatively their low-stress abrasion resistance as a function of chemical composition and hardness.ASTM G65Procedure A was used as the method of abrasion resistance evaluation.The most important variable in determining low-stress abrasion resistance was found to be chemical composition (microstructure)of the deposit.One and three layer deposits of high chromium cast iron and cobalt alloy based alloys have shown highest abrasion resistance,over2.5times higher than HARDOX400steel.Hardness has secondary effect on abrasion resistance and cannot be use as the abrasion resistance indicator.Dilution has an important effect on abrasion resistance of iron-based alloys.©2005Published by Elsevier B.V.Keywords:Surfacing;MCAW;Metal cored wires;GMA1.IntroductionSemi and automatic GMAflux and metal cored wire sur-facing is one of the most popular method of surfacing of new or worn machine parts,Fig.1[3–17].It is possible to deposit layers in all positions with efficiency from a few up to a dozen or so kilograms of weld metal deposit per hour[6].Modern metal cored wires allow to deposit layers pro-viding a broad spectrum of almost optional chemical com-positions,e.g.iron-based alloys including ferritic/bainitic alloys,martensitic alloys,mixed martensitic/austenitic al-loys,austenitic alloys,austenitic manganese alloys,primary austenite with austenite-carbide eutectic,primary carbides with austenite-carbide eutectic,nickel and cobalt based alloys and metal–ceramic materials,e.g.nickel or cobalt alloys with primary WC or W2C carbides[1–6].All these materials are GMA surfaced on new or worn working surfaces of machine parts or elements to provide specific properties as abrasive and adhesive wear resistance,erosion resistance,corrosion resistance,heat resistance and many of theirs combinations [1–17].It is reported that50–60%of machine elements are ∗Corresponding author.E-mail address:andrzej.klimel@polsl.pl(A.Klimpel).worn due to abrasive wear which has many forms includ-ing low-stress,high-stress,dry or wet abrasion[6].Abrasion resistance of GMA surfaced layers is a function of many factors but basic are chemical composition and microstruc-ture,which on other hand depend on GMA surfacing pa-rameters.The solidification morphology and as the result the microstructure of weld metal deposits depends on speed of surfacing,surfacing arc current and arc voltage(heat input of GMA surfacing).Additionally the heat input allows control-ling the shape of fusion line,penetration depth and dilution, thus chemical composition of the deposit.One of the primary criterions of determination optimal surfacing parameters,especially in case of surfacing of de-posits that chemical composition strongly differs from base metal chemical composition,is to provide minimal dilution of thefirst layer of deposit,Fig.2:U(%)=F BMBM R×100(dilution of the deposit by melted base metal),where F BM is the area of base metal melted,F R the area of reinforcement of the deposit(i.e.surfacing metal added).Dilution of the GMA metal cored wire surfaced deposit can be controlled from10to over40%,depending on surfacing parameters(heat input of surfacing)and technique0924-0136/$–see front matter©2005Published by Elsevier B.V. doi:10.1016/j.jmatprotec.2005.02.242A.Klimpel et al./Journal of Materials Processing Technology 164–165(2005)1056–10611057Fig.1.Scheme of GMA metal cored and flux wiressurfacing.Fig.2.Geometrical parameters of the stringer bead deposit:b ,width of bead face;h R ,height of bead reinforcement;h BM ,base metal penetration depth;F R ,area of reinforcement;F BM ,area of base metal melted.of surfacing [3–15].Technique of GMA cored wire stringer bead multi-layers surfacing makes possible to achieve dilution of second layer of deposit in the range of 5–15%but efficiency of GMA surfacing is lowest [4,6,13–15].Another solutions providing significant reduction of dilution is low heat input surfacing of stringer bead deposits and/or employing push technique of GMAsurfacing.Fig.3.Schematic diagram of ASTM G65Procedure A test apparatus.Thus,abrasion resistance and hardness tests of GMA cored wire surfaced single layer (high dilution)and three-layer (low dilution)stringer bead deposits four iron and two cobalt based hard facing alloys were done and compared to HARDOX 400steel abrasion resistance.2.Abrasion resistance testsTo determine quantitatively the wear resistance of GMA surfaced single and three layer stringer bead deposits of four metal cored wires EnDOTec DO*13,EnDOTec DO*16,En-DOTec DO*31and EnDOTec DO*329iron-based hard fac-ing alloys and EnDOTec DO*60and EnDOTec DO*70cobalt based hard facing alloys,Table 1,in comparison to HARDOXTable 1Classification,chemical composition,typical hardness and GMA surfacing parameters of the deposits of six metal cored wires of test coupons for the abrasion resistance tests as per ASTM G65,Procedure A Coupons designationChemical composition and typical hardness of the depositSurfacing parameters Current (A)V oltage (V)Heat input (kJ/mm)EnDOTec DO*13Fe +0.45%C,3.0%Si,0.5%Mn,9.5%Cr,0.02%P,0.01%S;56–58HRC160–17018.5–19.00.62EnDOTec DO*16Fe +0.3%C,0.5%Si,0.5%Mn,0.02%P,0.02%S,2.5%Cr,0.6%V ,4.0%W;48–50HRC 160–17019.0–19.50.63EnDOTec DO*31Fe +3.5%C,1.2%Si,0.8%Mn,0.2%Ni,30.0%Cr,0.02%P,0.01%S 55–60HRC160–17022.0–22.50.68EnDOTec DO*329Fe +0.4%C,0.5%Si,0.7%Mn,2.4%Cr,0.5%Mo,2.2%Co,0.5%V ,7.5%W;50–55HRC 140–15019.5–20.00.58EnDOTec DO*60Co +1.0%C,0.5%Si,0.8%Mn,0.01%S,29.0%Cr,4.5%W,3.0%Fe;40–42HRC 145–15020.5–21.00.58EnDOTec DO*70Co +1.7%C,0.5%Si,0.8%Mn,0.01%S,29.0%Cr,4.5%W,3.0%Fe;48–50HRC140–14519.5–20.00.60Remarks:welding speed of surfacing 5.0mm/s,all tested metal cored wires diameter =1.6mm.Shielding gas 97%Ar +2.5%CO 2,flow rate 18.0l/min.Wire stick out 22.0mm.Table 2Chemical composition wt.%,of the materials used as the base plates for GMA surfacing of metal cored wire deposits for abrasion resistance tests and the reference HARDOX 400wear plate Base and reference wear plate C Mn Si P S Cr Ni B Mo HBW S355NL0.18 1.360.450.020.020.090.10–––HARDOX 4000.141.60.70.0250.0100.500.250.0040.25370–4301058 A.Klimpel et al./Journal of Materials Processing Technology 164–165(2005)1056–1061Fig.4.Overview of ASTM G65Procedure A abrasion test apparatus.400wear plate wear resistance,Table 2,the tests of abrasive wear type metal–ceramic were conducted in accordance to standard ASTM G 65,Standard Test Method for Measur-ing Abrasion Using the Dry Sand/Rubber Wheel Apparatus,Figs.3and 4.Procedure A of the ASTM G65standard was chosen.Quartz Ottawa sand had tightly limited particle size in U.S.sieve size −50to 70(−300to 212m)and moisture content under 0.5wt.%was used,Fig.5.The rate of quartz sand flow through the special nozzle in the shape of thin layer between the test piece and a hard rubber wheel 229mm in diameter was adjusted at the rate 300–400g/min.For all of abrasion resistance tests of GMA surfaced de-posits of six metal cored wires,Table 1,the base plate was TStE 355steel,DIN 17102(S355NL-EN 10113),12mm thick,by 120mm wide and 150mm in length.AllGMAFig.5.A view of dry quartz Ottawa sand AFS 18/70used for G65tests,magnification 25×.Fig.6.A view of robotized GMA surfacing stand.surfacing was done using stringer beads,with no preheat and maximum interpass temperature of 250◦C for three lay-ers deposits.GMA robotized surfacing parameters of single layer and three layer stringer bead deposits were selected in the range of the field of optimal GMA surfacing parameters,Table 1,providing almost the same value of heat input of sur-facing.Robotized GMA metal cored wire surfacing was con-ducted on the welding stand equipped with TotalArc 25000CASTOLIN programmable power source and SRV6REIS welding robot,Fig.6.The 25mm wide and 75mm in length abrasion test coupons were cut from single and three layers deposits and all test coupons were surface ground smooth and weighed to the nearest 0.0001g as required by ASTM G65.Next abrasion resistance test was conducted.The force applied pressing the test coupon against the wheel was TL =130N (test load,TL)and 6000revolutions of the rubber wheel at 200rpm.After the abrasion resistance test,the test coupon was weighed at weight sensitivity 0.0001g,Figs.7and 8.Mass loss was reported directly and relatively in comparison to the mass loss of the reference HARDOX 400wear plate which is chosen as the reference material for all tested coupons of metal cored wires deposits,Table 2.Next the density of tested weld metal deposits and reference HARDOX 400wear plate was measured and abrasion tests results were reported as volume loss in cubic millimeters and Fig.9,by converting mass loss to volume loss as follows:volume loss (mm 3)=[mass loss (g):density (g /cm 3)]×1000.A.Klimpel et al./Journal of Materials Processing Technology164–165(2005)1056–10611059Fig.7.A view of test coupons of GMA surfaced one and three layers deposits by means of metal cored wires EnDOTec DO*13,EnDOTec DO*16,EnDOTec DO*031,EnDOTec DO*329and coupon of HARDOX400wear plate,after abrasion tests by means of dry quartz sand in accordance to standard ASTM G65, Procedure A.Fig.8.A view of test coupons of GMA surfaced one and three layers deposits by means of metal cored wires EnDOTec DO*60,EnDOTec DO*70wear plate, after abrasion tests by means of dry quartz sand in accordance to standard ASTM G65,Procedure A.1060 A.Klimpel et al./Journal of Materials Processing Technology 164–165(2005)1056–1061Fig.9.The influence of the chemical composition of the GMA surfaced one and three layers deposits of metal cored wires EnDOTec DO*13,EnDOTec DO*16,EnDOTec DO*031,EnDOTec DO*329,EnDOTec DO*60,EnDOTec DO*70,on the deposits abrasion resistance and surface hardness HV10in relation to the relative abrasion resistance of HARDOX 400wear plate.3.Conclusions(1)Low-stress abrasion resistance to metal–ceramic scratch-ing by means of dry Ottawa quartz sand in accordance to standard ASTM G65Procedure A of GMA surfaced single and three layers stringer bead deposits of all tested metal cored wires,Table 1,is exceeding over 1.22–2.83times abrasion resistance of HARDOX 400wear plate.(2)For all wires tested,but EnDOTec DO*31,three layersstringer bead deposits (low dilution)present almost the same abrasion resistance as one layer deposits (higher dilution),which is very positive indication of techno-logical features of wires,allowing to achieve expected rheological and mechanical properties just in the single layer deposit.On the other hand single layer deposit of EnDOTecDO*60wire has over 20%higher abrasion re-sistance than three layers deposit,probably due to lower dilution of the third layer deposit and as the result lower alloying of cobalt based deposit by iron of base metal.(3)The highest abrasion resistance is shown by metal coredwire EnDOTec DO*31of high chromium cast iron struc-ture and EnDOTec DO*70cobalt based alloy deposits.Single layer of EnDOTec DO*31deposit has 1.99times higher and three layers deposit has 2.83times higher abrasion resistance in comparison to abrasion resistance of HARDOX 400wear plate as this wire is designated to increase metal–ceramic abrasion resistance [6].(4)The lowest abrasion resistance is shown by metal coredwire EnDOTec DO*13martensitic steel structure de-posit and EnDOTec DO*329alloy steel structure deposit in the range 1.22–1.29times of abrasion resistance of HARDOX 400wear plate,in spite of very high hardness 590–620HV10,but it is still good result as the EnDOTec DO*13and EnDOTecDO*329wires are designated for applications demanding protective coatings to resist metal–metal friction,pressure and impact loading at high temperatures [6].(5)It has been proved that there is very reliable correlationbetween abrasion resistance and chemical composition (microstructure)of the GMA surfaced single and three layers deposits of all tested metal cored wires,Table 1,Figs.7–9,but on the other hand,hardness is very poor indicator of abrasion resistance,as the ratio of hardness to abrasion resistance (HR)which should be expected to be on the same level is much higher for deposits showing lower abrasion resistance,for example HARDOX 400wear plate shows HR =450,EnDOTec DO*13deposit shows HR =620:1.22=508.2but EnDOTec DO*70deposit HR =510:2.67=191,Fig.9.References[1]L.A.Dobrza´n ski,Podstawy nauki I 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