Effect of deposited Stellite-6 powder on microhardness and dilution rate on SS-316L substrate by TIG cladding

Purpose This study aims to examine tungsten inert gas (TIG) cladding on a steel substrate using a pre-placed powder method with Stellite 6 powder under various processing conditions. Design/methodology/approach The impact of processing current (PC), welding speed (WS), argon flow rate (AFR) and stand-off distance (SOD) was assessed using one-factor-at-a-time (OFAT) approach. A robotic TIG welding manipulator was used for precise control. The feasible ranges of PC and WS were 60–100A and 60–210 mm min−¹, respectively. Feasible ranges of AFR and SOD were 5–20 L min−¹ and 1–4 mm, respectively, for superior surface quality. Findings The results indicated that moderate heat input significantly improves hardness due to enhanced metallurgical bonding and controlled dilution. Maximum hardness of 415 was achieved at 90 A. Furthermore, hardness improved with increase in WS and was measured as 372 HV at 180 mm min−¹; further increase in WS led to an abrupt drop to 216 HV due to lack of fusion. Practical implications Cladding of Stellite-6 results in enhanced mechanical properties. It serves as an effective clad material in improving hardness and wear resistance with potential applications in industrial surface engineering. Originality/value An attempt is made to perform cladding of Stellite 6 powder on AISI 316L substrate material with the help of TIG process by using robotic TIG manipulator. Further dilution was a key factor to control surface properties. Moderate level of dilution was necessary for superior quality.