Mig Welding stands for Metal Inert Gas welding. In this welding process a wire is fed through a contact point to the work piece and a power source connected between them. When the wire contacts the work piece an electric arc is struck heating the wire and the surface of the work piece until it is molten. Wire is fed into this weld pool in processes that are usually either a short circuit or spray transfer mode.
Mig hardfacing can be done in a variety of ways. The basic process is the same but application methods vary
Mig Solid Wires. This process uses solid mig wire that has been pre alloyed to give a uniform material.
Hollow cored Wire. This material consists of a hollow tube of metal filled with alloys and hardfacing material. As the wire is melted the hardfacing materials solidify producing an overlay.
Mig wire with powder feed. In this process a powder feeder is added to the equipment to feed powder of hardfacing chips into the molten weld pool. By varying the type of wire and type of powdered or chips of materials a large variety of overlay products can be produced.
TIG stands for Tungsten Inert Gas. In this process an arc is struck between the tungsten and the workpiece. Wire, powder or a combination of the two can be fed into the weld pool to produce a hardfacing weld overlay
SAW Submerged Arc Welding is a high deposition process that is excellent for producing high volume products such as wear plate. A layer of flux is put on top of the work piece along with Hardfacing and alloying elements. A wire is fed into the flux until it contacts the work piece. The contact initiates an arc resulting in a weld pool with alloys and hardfacing products of the desired composition
PTA Plasma transferred arc welding involves use of a modified plasma Arc welding gun. In this process powdered materials are fed into a plasma welding arc and deposited into a weld puddle. This process can produce a range of products by varying the powdered consumable being fed into the arc.
Other
Thermal Spray
Plasma Spray
In the Plasma spray process a metal or ceramic is applied to a substrate with a high temperature arc. In this process the ceramic or metal is injected into the arc where it melts, and is propelled onto the substrate. When the material contacts the substrate it freezes solid forming a coating.
HVOF
High Velocity Oxy Fuel is a thermal spray process for applying materials like WC, Crc and metals to a substrate. The Deposits are typically quite thin (500 microns)but they are extremely wear resistant. The bond strength of the deposited material is significantly less than a welded overlay but there is no distortion due to weld shrinkage.
Flame Spray
In the flame spray process a metal or ceramic is applied to a substrate with a high temperature flame. In this process the ceramic or metal is injected into the flame where it melts, and is propelled onto the substrate. When the material contacts the substrate it freezes solid forming a coating. A variation of this is a spray fuse process whe a product is sprayed on first then heated until the powder is brezed to the surface.
Brazing
Brazing is a process where two metals joined by heating the components to above the melting point of the filler metal which flows through the join through capillary action
Flame Brazing
In this process a high temperature reducing flame is applied to the WC to heat the WC, braze and the substrate to the brazing temperature. Once at the brazing temperature the braze ‘wets’ the surface of the WC and substrate forming a strong bond on cooling.
Vacuum furnace brazing
In this process a vacuum furnace is used to heat the components to brazing temperature in a high vacuum. This prevents oxidation of the wear resistant parts and allows slow heating and cooling that prevents thermal shock failures that can occur with Flame and Induction Brazing.
Hydrogen Furnace Brazing
Operates in a similar fashion to the vacuum furnace but at atmospheric pressure and with a H2 atmosphere. A slight methane content may be added to the H2 to prevent carbon uptake from wear components.
Induction Brazing
A component is placed in an induction furnace and very rapidly heated to brazing temperature by an alternating current in a coil placed outside the component to be brazed. Induction Brazing is suited to high volume repetitive processes and can produce highly reliable and consistent results. Typical brazing times run from as little as 1 second to 3 minutes depending on brazing material, system and components.
Sintering
Cermet
MIM
Ceramic
HIP ing
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