Microstructure, Hardness, and Wear Behavior of Layers Obtained by Electric Arc Hardfacing Processes

Hardfacing is a welding-related technique aimed at depositing a harder and tougher layer onto a softer, less wear-resistant substrate or base metal. This process enhances the abrasion resistance of the component, increasing its durability under working conditions. A key feature of hardfacing is dilution, which refers to the mixing of the hardfacing layer and the base metal. In this study, shielded metal arc welding (SMAW) was employed to hardface structural steel using chromium carbide vanadium consumables, with results compared to AISI D2 cold-work tool steel. Four different SMAW parameters were tested, and the abrasive test was conducted against SiC discs. Wear rate, represented by the wear loss rate, was correlated to microstructure, scanning electron microscopy, energy-dispersive X-ray spectroscopy, hardness, microhardness, and surface roughness. The results showed that key SMAW parameters, such as welding speed and current, significantly influence wear resistance. Specifically, slower welding speeds and higher currents, which result in greater heat input, led to the increased wear resistance of the deposited layer through the mechanism of the inoculation of larger and harder carbides.