Protected by NDA
Due to being protected by NDA, this project is only partially available for publishing online. Some details have been provided to give you an idea of the scope of the project. If you would like to discuss anything further please don't hesitate to contact me and I will provide what information I can.
WEAR RESISTANT MATERIAL
COMPOSITE WELD OVERLAY
By GET Overlays
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Traditional metal arc welding (GMAW) carbide impregnation overlay is underperforming due to preferential matrix wear leading to carbide loss. The proposed solution to this problem is the use of a specific welding electrode in place of the current low alloy consumable and optimization of welding parameters to suit it. This allows for minimal changes to the current operation while improving performance.
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The increased [element1] and [element 2] content serve to increase the hardness of the matrix by increasing the martensite content of the weld and forming complex carbides. Both of these features increase the abrasive wear resistance of the matrix.
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This leads to improved performance and increased service life for certain operating conditions. After investigation, the most promising solutions to improve performance were either: 1) a modification of the matrix material or 2) the modification of the hardfacing particles.
Upon further consideration, changing the matrix, specifically by adding [element1] and [element1] was considered the most promising option. Research has found that this combination would result in improved wear rates. Furthermore, as this solution does not have a significant impact on the current process, existing safety considerations would be sufficient.
Economic evaluation of this solution has found that use of the new electrode will increase material costs. The economic viability of this solution will be dependent on several variables.