Where direct fusion welding is not appropriate, as in the case of an extremely hot-crack-sensitive

casting, other
approaches might prove useful. One option is to "butter" the area of the crack-sensitive casting to
be joined, using a
consumable of a less crack-sensitive material. This "buttering" involves surfacing the casting
locally with a consumable
before fabricating the actual weld joint. With no joint present during the buttering operation, the
restraint on the
solidifying surface pass and the underlying HAZ of the casting can be quite small and defects
(fusion zone and HAZ hot
cracks) may be avoided. This surfaced area can be built up slowly to a thickness where it can
then be prepared as a joint
for subsequent welded attachment. Additional information on buttering can be found in the
article "Hardfacing, Weld
Cladding, and Dissimilar Metal Joining" in this Volume. As another option, an insert of a less
hot-crack-sensitive alloy
can be inertia or friction welded onto the mating surface of the hot-crack-sensitive casting. This
insert could then be
prepared for subsequent fusion welding to the required structure. These options are contingent
upon the availability of consumable materials that are acceptable in the service environment.

SFA - 5.13

A7.3.1 ENiCr-C Electrodes

A7.3.1.1 Characteristics. Undiluted weld metal of this composition exhibits a structure consisting
of chromium carbides and chromium borides in a nickel-rich matrix. The nickel base and high
chromium content give these deposits good heat and corrosion resistance. Care should be taken
when cooling hardfacing deposits because of a tendency to stress crack. This alloy possesses
excellent resistance to low stress abrasion.

SFA - 5.21

A7.1.8.2 Applications. A general purpose hard facing alloy which can be used where limited
stress-relief cracks (checks) are acceptable but severe abrasion is not encountered.

Thanks & Best Regards,

Mr. Swamy mentioned the methods of fabrication to avoid cracks of overlays on sensitive base
metal which is not the case here.

Chromium Carbide Deposit will crack whatsoever the method is. That's inherent to this material
but the point is you shall manage these cracks. If you decide to avoid these cracks, maybe you
can manage it for a while but suddenly you will see a big wide crack tearing your workpiece
apart. So you have to accept its presence and control it in your favor.

You should be critical on the crack size (width and length), quantity per square feet and their
direction. It means that ideally it is better to have many short perpendicular cracks rather than a
few long parallel cracks.

How can you do that...?

For this purpose, you want cracks to be formed as soon as possible. Don't hold them back...!!!
Do not use much preheat unless your base metal calls for it (I don't think your base metal needs
preheat), interpass temperature shall not exceed a certain limit (like Austenitic stainless steels).
Some people actually use water to quench these overlays right after the arc is off and inspect the
cracks after depositing each lb of filler metal and before they continue overlaying and it
works...!!!

It's better to have a crossed pattern for weld directions. Normally cracks appear in transverse
direction (with reference to weld direction) so if you want to avoid parallel cracks, you should
weld in different directions. Chess pad pattern works well.

I think you got the idea...

Check-cracking, or checking as it's sometimes called, occurs in the metal carbide families and
can be seen as cracks that are perpendicular to the bead length. They generally occur from 3/8 to
2 inches apart and are the result of high residual stresses of hard-facing weld metal as it cools.
Other alloys such as the austenitic and martensitic families, don't crack when applied with proper
welding procedures but for many of chromium carbide alloys, check-cracks appear when cooled
to moderate temperatures; this is normal.

Again, be careful if you try to stop this cracks, the residual stress will build-up and whatever you
do, it will eventually crack, this time it will be a wide long crack that tears your work-piece
apart...!!!

Check cracks propagate through the thickness of the weld bead and stop at the parent metal, as
long as it's not brittle (like your case). In cases in which the parent metal is hard or brittle, you
should select a buffer layer of a softer, tougher weld metal. Like what Mr. Swamy
recommended, Ni-base or austenitic buffer family are good choices for a buffer deposit.

Regards