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Welding International
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To cite this article: Jacek Grka, Tomasz Kik, Artur Czupryski & Wojciech Foreiter (2014) Technology of welding hard
wearing plates, Welding International, 28:10, 749-755, DOI: 10.1080/09507116.2012.753223
To link to this article: http://dx.doi.org/10.1080/09507116.2012.753223
The technology of welding of abrasion-resisting plates with the use of different filler metals designed for providing high
wear resistance of the top layer and good plastic properties of the parent material is presented. To this end, we made test
joints which were subjected to metallographic examination, mechanical testing, hardness measurements and testing of wear
resistance of the type metal mineral in accordance with ASTM G65-04 standard. In each case, the weld joining the wear
resistant layer was made with the use of an XHD 6710 covered electrode. For making the weld joining of the parent material
of the abrasion-resisting plate, we applied austenitic and ferritic perlitic filler materials in the form of covered electrodes
and solid wires for gas shielded arc welding. The tests have shown that the XHD 6710 electrode can be used for joining of
top layers of abrasion-resisting plates providing their high wear resistance. For interpasses and filler passes, it is
recommended to use austenitic filler metals which are characterized by very good plastic properties. Moreover, they reduce
the mixing ratio of the weld metal and the material of the abrasion resistant layer.
Introduction
Hard wearing plates are layered liners that combine ease of
installation with very high resistance to abrasion and
erosion. They are made by coating easily weldable, loadbearing steel sheets with a wear-resistant layer of alloyed or
cermetallic material. Two methods are used to obtain very
durable coatings arc welding and diffusion bonding of
cermetallic powders in a vacuum oven [1 4]. Regardless of
the method of production, hard wearing plates are
characterized by their very high quality of manufacture,
constant over the entire surface of the sheet, identical for
plates of the same type [5,6]. The high resistance of the
plates to abrasive wear is achieved by the presence of very
hard and complex carbide phases (1500 3000 HV) in the
surface layer, 2 3 times exceeding the hardness of most
common abrasives. A very important factor improving the
durability of abrasion-resistant layers is the ordered
distribution of hard phases. The ability to control the
Figure 1.
Own research
The aim of this study was to test the applicability of
shielded electrodes XHD 6710 for wear resistant layers
[16] and austenitic (CastoMag 45554, Xuper Nucleo
Examples of construction components with hard wearing layers created by welding [5].
J. Gorka et al.
750
Abrasion resistant layer
60
(a)
Steel S235JR
12
(b)
Steel S235JR
Microstructure of chromium
cast iron of the abrasion
resistant layer
1
Substrate ferriticpearlitic
microstructure of substrate
material
Cr
22
Nb
7
B
1.8
Fe
Rest
Testing
In order to determine the effect of the welding method and
the type of binder on the properties of welded joints of
hard wearing steel sheets, four test joints have been
prepared and designated as follows.
P1: Test joint welded from the side of the base using
shielded electrodes Xuper Nucleo Tec 2222 and using the
Table 2.
P2
P3
P4
Plate
designation
P1
Pass no.
Welding
procedure
Electrode wire
diameter (mm)
Arc voltage
(V)
Current
(A)
1
2
3
1
2
3
1
2
3
1
2
3
111
135
111
111
135
111
135
135
111
135
135
111
3.2
1.0
3.2
3.2
1.0
3.2
1.0
1.0
3.2
1.0
1.0
3.2
26.2
25.6
25.8
26.0
24.2
26.2
25.5
26.1
25.8
25.4
25.2
25.9
95
228
112
93
231
118
229
227
122
226
228
119
Consumable
material
Xuper Nucleo Tec 2222
CastoMag 45250
XHD 6710
Xuper Nucleo Tec 2222
CastoMag 45554
XHD 6710
CastoMag 45554
CastoMag 45554
XHD 6710
CastoMag 45250
CastoMag 45250
XHD 6710
Welding International
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9 10 11
9 10 11
steel S235JR
Metallographic examination
The samples for metallographic examination were
prepared by grinding, polishing and etching in an aqueous
Figure 5. Microstructure of weld joints of hard wearing plates, from left: abrasion resistant weld joint, transition from weld material to
hard wearing plate, weld joining the substrate material. Etching: FeCI3, magnification 200 , welding parameters (see Table II).
J. Gorka et al.
752
Strength tests
The static tensile test (according to standard PN-EN
895:1995) and the normal bend test on the side of the face
and root of the weld joints were carried out on the
INSTRON 4210 test machine. The test results are shown
in Tables 4 and 5. Due to the construction of the hard
wearing plate, loads can be carried only by the substrate
material (steel S235JR).
Hardness measurement
The hardness measurement was performed on a cross
section of the joint using the Vickers method (HV1)
on a WILSON WOLPERT 401 MVD machine, with a
load of 10 N and load time of 15 s. The measurement
Table 3.
HV1 hardness measurement test results in a cross section of the weld joint.
Hardness HV1
Sample
designation
Measurement
line
P1
I
II
I
II
I
II
I
II
P2
P3
P4
Table 4.
Joint P2
Joint P3
Joint P4
Table 5.
R/1
R/2
R/1
R/2
R/1
R/2
R/1
R/2
Joint P2
Joint P3
Joint P4
10
11
152
824
144
806
140
835
138
773
138
832
151
808
138
822
142
825
143
879
148
812
141
844
141
864
288
884
160
972
136
880
143
986
256
892
178
924
193
866
192
948
265
880
184
912
223
932
197
804
304
876
187
939
220
873
224
838
291
868
156
968
132
900
134
840
145
854
147
809
140
836
140
822
146
840
150
810
137
840
139
814
150
842
146
808
140
841
142
802
Active cross-section
S0 (mm2)
Breaking force
Fm (kN)
Tensile strength
Rm (MPa)
168
168
168
168
168
168
168
168
55.15
57.12
60.21
63.02
52.70
54.67
55.18
57.87
325
337
360
371
324
335
330
342
Break location
Outside
Outside
Outside
Outside
Outside
Outside
Outside
Outside
the
the
the
the
the
the
the
the
weld
weld
weld
weld
weld
weld
weld
weld
Sample designation
Joint P1
Tensile strength test results for weld joints of hard wearing plates.
Sample designation
Joint P1
Bending side
FBB1
FBB2
RBB1
RBB2
FBB1
FBB2
RBB1
RBB2
FBB1
FBB2
RBB1
RBB2
FBB1
FBB2
RBB1
RBB2
Face
Face
Root
Root
Face
Face
Root
Root
Face
Face
Root
Root
Face
Face
Root
Root
Comments
Break
Break
Break
Break
Break
Break
Break
Break
Break
Break
Break
Break
Break
Break
Break
Break
in
in
in
in
in
in
in
in
in
in
in
in
in
in
in
in
material
material
material
material
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Figure 7. View of the test station for testing resistance to abrasive wear (metal mineral) in accordance with standard ASTM G65-04.
Summary
The macroscopic metallographic examination of welded
joints of hard wearing plates welded with selected binders
have shown that during formation of the fusion layer
(Figure 3), the binder material, the substrate material and
the wear resistant material partially melt and mix together.
In the case of joints P1, P3 and P4 (fusion layer created
using GMA welding method), the content of the wear
resistant layer material in the weld is high, which is related
Test results of abrasive wear resistance test for weld joints of hard wearing plates, in accordance with standard ASTM G65-04.
Sample
designation
Hard wearing plate
Abrasion resistant weld
Sample no.
Sample mass
before test
(g)
Sample mass
after test
(g)
Mass loss
(g)
P0-1
P0-2
P1-1
P1-2
P2-1
P2-2
P3-1
P3-2
P4-1
P4-2
109.7678
110.0687
127.3744
123.7821
118.5109
105.4929
138.2340
141.5862
120.6470
143.2293
109.6160
109.9137
127.2277
123.6355
118.3555
105.3311
138.0895
141.4443
120.5059
143.0852
0.1518
0.1550
0.1467
0.1466
0.1554
0.1618
0.1445
0.1419
0.1411
0.1441
Average
mass loss
(g)
Average
volume loss
(mm3)
0.1534
20.9849
1.00
0.1466
19.9184
1.0549
0.1586
21.5489
0.9738
0.1432
19.4565
1.0800
0.1426
19.3750
1.0845
Relative resistance to abrasive wear compared to the material of the abrasion resistant layer of the hard wearing plate.
Relative abrasive
wear resistancea
754
J. Gorka et al.
References
Figure 9.
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