Consumables for Harsh Industrial Work

Stoody®, an ESAB (Florence, SC) brand, has added new nickel-based tungsten carbide consumables to its product line, including several new wire formulations, as well as new PTA and laser cladding powder families, all designed for extreme abrasion resistance. These nickel-based tungsten carbide consumables are developed for and utilized in some of the harshest industrial applications. Recognized for durability and performance in the face of extreme abrasion, impact and other wear conditions, these stick electrodes, wires and now PTA and laser cladding powders are used to restore damaged components and to overlay parts to extend serviceable life.

Stoody’s premium nickel-based tungsten carbide consumables line includes the following recently released wires and powders:

• 155FC (25 percent WC) – A gas shielded build up and buffer layer alloy, 155FC is ideal for thick build up deposits up to four layers. This alloy is perfect for use as an underlay for a hardfacing overlay alloy for extreme wear resistance. It has a maximum hardness of 35-45 HRC.
• 160FC (48 percent WC) – Originally available for the GMAW process and developed in conjunction with the 155FC build-up alloy, this highly wear resistant hardfacing overlay wire is now available in an open arc formulation. It has a maximum hardness of 40-50 HRC.
• 160FS (50 percent WC) – This entirely new wire consumable for the GMAW process incorporates spherical tungsten carbides that deliver better performance in friction applications and improved wear performance compared to standard nickel-based tungsten carbide alloys. It has a maximum hardness of 40-50 HRC.
• 6040-PLC, 6040-PLM, 6040-PLS – Stoody recently introduced its first PTA and laser cladding powder consumables available in a 60 percent tungsten carbide, 40 percent nickel alloy formulation. The PLC blend incorporates standard cast and crushed eutectic tungsten carbides in the matrix. The PLM variant incorporates macrocrystalline tungsten carbides more appropriate for high power systems. The PLS formulation contains spherical tungsten carbides especially suited for laser cladding operations. It has a hardness range of 40-45 HRC. Potential applications include petroleum downhole tooling and oil sands components; parts used in ore processing, cement production, brick making, pigment production, steel mills, pulpers and other harsh applications.
• 6030-PLC, 6030-PLM, 6030-PLS – The 6030 powders are also 60/40 blends of tungsten carbide in a nickel alloy and can be formulated with the same three choices of tungsten carbides as the original 6040 powders. The primary difference is the 6030 powders form a ductile nickel-chrome alloy matrix. It has a hardness range of 30-35 HRC. The 6030 powder formulations come in –PLC (standard cast and crushed eutectic tungsten carbides), –PLS (spherical carbides), and –PLM (macrocrystalline) formulations.
• 6051-PLC, 6051-PLM, 6051-PLS – Like the 6040 and 6030 powders, the new 6051 blends are formulated with the 60/40 tungsten carbide and nickel alloy matrix, with a notable difference: 6051 powders are chromium-free formulations with the same tungsten carbide options available to choose from – standard cast and crushed (-PLC), macrocrystalline (-PLM), or spherical (-PLS). It has a hardness range of 48-52 HRC.

The 6040, 6030, and 6051 formulations are currently available in either a 10 lb single carton or a 40 lb standard four-pack.

Stoody also offers cobalt-based consumables under the Stoodite label in bare rod, coated electrode, gas-shielded, and submerged arc wire forms. A new line of four cobalt-based PTA and laser cladding powders have been created for advanced welding processes. Stoodite Co01-PL offers abrasive wear resistance, high temperature hardness and solid particle erosion wear resistance. Stoodite Co06-PL produces a medium hardness deposit for high temperature applications, with good abrasion, impact, chemical and mechanical wear resistance. Stoodite Co12-PL delivers a high hardness deposit and high temperature, abrasion, mechanical wear and corrosion resistance. Rounding out the cobalt-powder family is Stoodite Co21-PL, a low-carbon austenitic alloy that work hardens. The deposit offers high temperature strength and impact resistance plus anti-galling, corrosion and cavitation resistance makes Stoodite Co21-PL the ideal choice for fluid control valve components. Stoodite powder formulations are bottled in 11 lb increments and are available in either an 11 lb single carton or a 44 lb standard four-pack.

Stoody has also added the new 625-T1C gas shielded flux-cored joining wire that is specifically designed for the all-position welding of Alloy 625 and dissimilar metals using 100 percent CO2 shielding gas. The 625-T1C project was initially driven by direct inquiries from the Asian marketplace, where mixed shielding gases are more expensive and at times harder to obtain than CO2. This product builds on the 15 years of experience the company has in making nickel based flux cored wires. Other notable features of the 625-T1C wire include a composition that results in an all-weld deposit with iron content below one percent, which is essential for applications requiring enhanced corrosion resistance. The 625-T1C is available in 0.045 in (1.2 mm) diameter on 33 lb (15 kg) wire baskets. Classifications include AWS A5.34/A5.34M:2013; ENiCrMo3T1-1; and, ISO: TNi 6625-11. Typical applications include:

• Joining nickel-chromium-molybdenum alloys
• Welding clad sides of joints in steels clad with Ni-Cr-Mo metal
• Surfacing steel with Ni-Cr-Mo weld metal
• Joining steels to nickel based alloys
• Joining 9 percent nickel steels for cryogenic service

This wide range of tailored hardfacing and high alloy joining solutions address wear caused by abrasion, impact, corrosion and heat. These welding consumables include wire and stick electrodes, as well as powder alloy products that support the steel, power generation, petroleum oil and gas drilling, recycling, cement, pulp and paper, agricultural, metal casting, construction and other industries worldwide.

Stoody | ESAB Welding & Cutting Products, PO Box 100545, 411 South Ebenezer Road, Florence, SC 29501-0545, 843-669-4411, Fax: 843-664-4258, www.esab.com.