FILARC flux - Esab

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FILARC flux- andmetal- coredwelding wiresFILARC gas- and self shieldedcored wires for hardfacingContents page 4Previous pageNext pageThe FILARC cored wires, described in thissection, provide substantially increasedproductivity when applying wear resistantalloys to surfaces of components subjectto abrasion, impact, heat and corrosion, ora combination of these.Some wires are available either as metalcoredversions using CO 2 or Ar/CO 2shielding gases (PZ 61xx), or rutileversions designed as selfshielding typesfor outdoor use (PZ 63xx).Available wire sizes are 1.2, 1.6 and2.4mm, depending on composition andintended application.Due to the high filling ratios, depositionrates can exceed 10kg/h at 100% dutycycle.Production of equipmentRolled, machined, cast or forged parts canbe hardfaced easily by hand when selectedareas are involved. Deposition rates willbe far higher than with stick electrodes,with further economy gained by avoidingstub losses, and no deslagging whenusing metal-cored wires.For rollers, or larger flat areas, mechanisedoperation can provide substantially increasedproductivity, and no deslagging.Productivity will often exceed submergedarc welding on rollers up to 500mm diameteror higher. The 1.6mm size is usuallyadopted.For large flat areas using broadly weavedruns, the 2.4mm size used at 500 to 600Amay prove most economical.Maintenance and repair workRutile, selfshielding wires avoid the needfor gas supplies and provide depositionrates far exceeding stick electrodes. The1.6mm size can provide horizontal-verticalwelds, also build-up of wear/abrasionresisting patterns on blades, etc.For building-up teeth or other work wherecopper moulds can be employed, the2.4mm size welded with a long stick-outbrings the fastest, most economical deposition.Choice of material depends on the propertiesrequired, in respect to:• Resistance to abrasive wear,i.e. hardness• Impact resistance, i.e. toughness• Resistance to heat and corrosionFlux and metal-cored wires are listed inthe table on page 102-103 together withequivalent stick electrodes and solid MIGwires. They are described in detail onfollowing pages.The chemical and mechanical propertiesdetailed, relate to pure weld metal. Inpractice these figures will be achievedwith the third layer. The first and secondlayer will show lower values, due to dilutionwith the base material. Also, the coolingrate will, in many cases, influence thestructure of the hardfacing metal.100
FILARC flux- andmetal- coredwelding wiresContents page 4Previous pageNext pageRebuilding the core of a stone crusher for acement plant at Carrières de Ciment Belge,Gaurain-Ramecroix in Belgium. Here, FILARCPZ6358, 1.6mm was applied to renew the bottomcircumference by approx. 50mm thickness.The welding areas were brought to thedownhand position; a special mould supportedthe weld metal to obtain the required profile. Afinal layer was deposited with PZ6154, toachieve initial wear resistance until the16%Mn/16%Cr alloyed weld metal underneathhas sufficiently work-hardened during service.The repair job took some 900 hours and involved1240kg of cored wire. The total cost forrepair amounted to 3 million BFR, while thepurchasing price for a new core was some 12million BFR. A cost calculation for repair withstick electrodes amounted to 6 million BFR.101
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