Influence of Process Variables in Flux Cored Arc Welding of Hardfacing Deposits

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Abstract
A lack of knowledge and objective data on the effects of welding process variables in the application and performance of weld deposited hardfacings has led to many past failures and a subsequent mistrust of the technology. This paper sets out, first, to review both the influence of welding process variables in hardfacing and the important characteristics and properties which determine the effective performance of a hardfacing deposit. Second, the results are presented of a full factorial experiment, which was performed in an effort to evaluate and interpret the effects of arc current, voltage, and polarity, as well as of travel speed, torch stand-off distance, and preheat, on the nature and properties of a commercial flux cored arc welded hardfacing deposit. In this programme, the effects of the welding parameters were evaluated with the aid of a number of computer analyses, with arc current, voltage, and polarity being shown to have the greatest effect: a high arc current (360 A) gives the most satisfactory deposit in terms of weld metal dilution, hardness, and porosity, as well as of both deposition rate and efficiency, provided that electrode negative arc polarity is used, together with a low (24 V) arc voltage. In attempting to achieve more cost effective use of hardfacings in abrasive wear resistant applications, both the potential of this approach and the value of the results obtained are clearly demonstrated.

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