Quantitative Assessment of the Influence of Plasma Hardfacing Parameters on the Metallurgical Melting of an Austentic Steel Coating with a Substrate Material Made of C45 Steel

Weld surfacing is the process of applying a layer of metal to the surface of metal objects by simultaneously melting the substrate. As a result of this process, the metal content of the padding weld can be as high as several tens of percents. It is a method used to regenerate machine parts and improve the properties of the surface layer, increasing its resistance to abrasion, corrosion, erosion, and cavitation. It also supports the repair and creation of permanent protective coatings in the engineering, automotive, energy, and aerospace industries. This makes it possible to repair damaged parts instead of completely replacing them, saving time and production costs. Plasma surfacing technology is used for components that require high hardness and corrosion resistance under various environmental conditions. Plasma wire surfacing is not sufficiently presented and described in the current literature, which creates problems in determining the appropriate process parameters. The influence of variable plasma surfacing parameters on steel C45 significantly affects surfacing weld geometry, the dilution factor, and microhardness. Higher currents can increase the dilution factor, integrating more base metal into the weld pool, which may alter the chemical composition and mechanical properties of the weld. Variations in surfacing speed and heat input also affect the microhardness of the surfaced joint, with higher heat inputs potentially leading to softer welds due to slower cooling rates. Optimizing these parameters is essential to achieving desired surfacing weld characteristics and ensuring the structural integrity of C45 steel joints. This paper presents the influence of varying plasma surfacing parameters on the surfacing geometry, the dilution factor, and microhardness. The tests were carried out on a Panasonic TM-1400 GIII automated surfacing machine with CastoMag 45554S solid wire as the filler material. Flat bars of C45 steel were prepared, and then the variable parameters of the surfacing process were developed. Tests were carried out to determine the dilution factor, followed by microhardness measurements. The results showed a significant dependence of the effect of the parameters on the surfacing geometry and the dilution factor.

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Development of a Mathematical Model of the Self-Shielded Flux-Cored Arc Surfacing Process for the Determination of Deposition Rate

Szymura,

Czupryński,

Ochodek

2024

Materials

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The article presents a method of developing a mathematical model of the arc surfacing process performed using the self-shielded flux-cored filler metal wire with the chromium cast iron (Fe15) weld deposit. A three-level design (static, determined, and complete) was used to determine the function of the test object, thus enabling the simulation of deposition rate in relation to wire feed speed and electrode extension. The deposition rate for the specified set of surfacing parameters amounted to between 4.31 kg/h and 11.25 kg/h. The study was also concerned with identifying the effect of the significance level of test factors and interactions between them on the resultant factor, as well as an assessment of the adequacy of the test object function. In relation to significance level α = 0.01, regression coefficients b0, b1, b2, and b11 significantly affected the deposition rate of the surfacing process. Coefficient b22 was significant at a level of 0.40, whereas coefficient b12 was significant at a level of 0.15. The mathematical model presenting the effect of wire feed speed and electrode extension, as well as interactions between them on the deposition rate of the surfacing process, was adequate for the adopted level of significance α = 0.05.

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Quantitative Assessment of the Influence of Plasma Hardfacing Parameters on the Metallurgical Melting of an Austentic Steel Coating with a Substrate Material Made of C45 Steel

Cited by 4 publications

References 4 publications

On the impact of stack patterns on the microstructure and wear performance of Colmonoy 6 coatings deposited on SS 304 via PTAW

On the impact of stack patterns on the microstructure and wear performance of Colmonoy 6 coatings deposited on SS 304 via PTAW

The Influence of Variable Plasma Welding Parameters on Weld Geometry, Dilution Factor, and Microhardness

Development of a Mathematical Model of the Self-Shielded Flux-Cored Arc Surfacing Process for the Determination of Deposition Rate

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