Hardfacing often appears uneven and rough because it builds up material across the surface. Unlike conventional welds, the goal is durability and wear resistance rather than smooth seams.

Hardfacing is suitable for steels (carbon, alloy, stainless, manganese), cast iron, nickel-based alloys, and copper-based alloys. Materials that are too soft or used in non-wear-critical applications are generally not suitable.

Hardfacing is primarily used on high-wear components exposed to abrasion or impact. It is not effective for parts damaged by flexing or sheer stress alone.

Common processes include submerged arc welding and flux-cored arc welding. Other methods like plasma arc, laser welding, or brazing can also be used. The key factors are heat control and deposition rate to ensure strong, durable wear layers.

All metal parts even with normal use will wear as time goes by. This may cause them to lose their functionality and as a result, the need for a new part.

In certain industrial applications, like in mining or agriculture, this may happen more frequently. Hardfacing can be an ideal option for any metal part that may wear for being used. In short, hardfacing can help to:

• Spend less downtime for replacing worn or broken components
• Store fewer spare parts to inventory, because they are not needed
• Longer equipment lifespan

Hardfacing is used for a wide range of applications, but we can highlight some examples.

Excavator plowshare
These parts suffer abrasion daily like any other construction equipment. The constant abrasion and erosion due to its daily outdoor heavy duty may significantly reduce the dimension and strength of the piece.
By hardfacing these parts, the total machinery lifespan can be extended many times, with a very reduced investment.

Sugar cane crusher roll
This part is constantly exerting pressure to mill the cane to extract the sugar to process. The sugar cane is a strong plant that can put these metal-made parts to the test.
Hardfacing is the usual procedure to extend the life of these parts, lowering production costs and downtime.

Mining crushing rolls
Mining is an industry quite related to hardfacing. The material obtained from the mine should be crushed to be processed.
Even with being made of hard material, in a short time these rolls are worn down because they deal with strong minerals all day long. So, more than a possibility, hardfacing is a must for mining crushing rolls.

There are several techniques and methods for applying hardfacing. The one you should choose will depend on your equipment and needs. Let’s talk about the techniques first.

Wear is typically caused by abrasion, impact, or metal-to-metal contact. Heat and corrosion can also contribute but are less common in hardfacing applications. Multiple wear types can occur simultaneously, such as abrasion and impact on excavator blades.

The ideal hardfacing machine handles long duty cycles, delivers consistent deposition, and minimizes the heat-affected zone. High-power welders (e.g., 220V) are generally more efficient, but most industrial-grade welders can perform hardfacing effectively. Equipment rentals can help test different machines before purchase.