Hardfacing

WALKSON can provide specially formulated Tungsten Carbide Overlay (TCO) applied by Plasma Transferred Arc Welding (PTAW) process on any casting or fabrication part surface to increase the wear-resistant property of the part.

For extremely abrasive applications, the overlay properties in the following chart will be used. The lifecycle of this type of overlay by PATW welding is 5-6 times longer than Chrome Carbide Overlay. Typical Applications of this kind of overlay are Slurry line, slurry pump suction and discharge spool, wear spool, spray nozzles.

Manufacturing and steel industries benefit from hardfacing in rollers, dies, and cutting tools, ensuring efficiency and cost savings. Additionally, it enhances components in oil, gas, and power generation, such as valves and turbine blades. Hardfacing minimizes maintenance, extends equipment lifespan, and reduces costs, making it indispensable for industries demanding reliable, high-performance machinery.

Mining and Quarrying Mining and quarrying operations are particularly demanding, with equipment exposed to extreme wear, abrasion, impact, and even corrosion. Hardfacing plays a crucial role in enhancing the durability and performance of critical components in these industries, where downtime and frequent replacement of parts can be costly. Learn More >

Construction and Earthmoving Construction and earthmoving industries rely heavily on heavy machinery and equipment that endure extreme conditions, including abrasive wear, impact, and high stress. The frequent contact with soil, rocks, concrete, and other abrasive materials leads to significant wear on components. Learn More >

Metal Recycling and Waste Processing Metal recycling and waste processing industries are characterized by the processing of a wide variety of materials that are often tough, abrasive, and mixed with metals, plastics, wood, or other challenging substances. Learn More >

Agriculture and Forestry In the agricultural and forestry industries, machinery and equipment are exposed to extreme operating conditions, including abrasive wear, impact, and corrosion. Learn More >

Power Generation and Cement Manufacturing Power generation and cement manufacturing are two industries that involve complex machinery and equipment subjected to extreme wear and stress. In power generation, particularly in coal-fired and thermal power plants, equipment faces high-temperature conditions, abrasive materials, and impact forces. Learn More >

Oil and Gas The oil and gas industry involves the extraction, processing, and transportation of oil, natural gas, and petrochemical products. The equipment used in this industry is subjected to some of the harshest operating conditions, including high pressures, extreme temperatures, abrasive materials, and corrosive environments. Learn More >

References of PTA Process

[1] Plasma transferred arc welding—modeling and experimental optimization. [J] J. Wilden, J. P. Bergmann & H. Frank. December 2006.

[2] Microstructure and wear properties of nickel-based surfacing deposited by plasma transferred arc welding. [J] Chen Guoqing, Fu Xuesong, Wei Yanhui, Li Shan, Zhou Wenlong. 15 August 2013, Pages S276-S282.

Transferred VS. Non-transferred Plasma Arc Welding

The main arc in TPAW is established between the tungsten electrode and the guide electrode. Compared with non-transferred plasma arc welding (NPAW) where one of the arc terminals is a nozzle, the workpiece is not connected to the circuit, and the energy loss is less than NPAW.
As the welding current and plasma gas flow rate increase, the diameter of the ablation zone of the TPAW (ie, the energy received by the workpiece) is much larger than the diameter of the NPAW. The MZ area and HAZ area of the TPAW weld are smaller, but the penetration depth of the PAW weld is similar.
Under the same parameters, the MZ or HAZ cannot be observed in the NPAW weld, indicating that the total heat input distribution of TPAW is much larger than that of NPAW . This trend provides a possible way to better control the energy of the plasma arc and expand the application of the plasma arc.

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