Leading Manufacturer of Hardfacing Welding Wires in India

Applications of Hardfacing Welding Wire

Ultramet Welds hardfacing welding wire and hardfacing flux cored wire are used in a wide range of industries where components are exposed to severe operating conditions. Common applications include:

Mining and Quarrying:
Used to protect crusher hammers, shovel teeth, and excavator buckets from abrasive rock and ore materials.

Cement and Construction:
Applied on roller presses, kiln tires, fan blades, and concrete mixers to enhance resistance to abrasion and erosion.

Steel and Power Plants:
Ideal for repairing coal crusher hammers, pulverizer parts, and conveyor systems subjected to continuous impact and wear.

Agricultural and Forestry Equipment:
Used on ploughshares, tillers, and chippers to prevent excessive wear in soil and wood contact operations.

Sugar and Paper Industries:
Improves the lifespan of cane knives, shredder hammers, and rollers exposed to fibrous abrasion.

In every industry, Ultramet Welds hardfacing wires help reduce downtime, increase equipment efficiency, and cut operational costs.

Ultra Hard Facing 350: Impact-Resistant Hardfacing for Mixed-Duty Applications

Application Profile: Crusher rollers, dozer blades, excavator teeth, agricultural tools, railway track components

The 350 grade represents a controlled balance between hardness and toughness, achieving a deposit hardness of 28–35 HRC. This grade is specifically formulated to resist moderate abrasion while maintaining resistance to impact-induced fracturing, a critical requirement in applications where cyclic loading and material shock are operational realities.

Technical Characteristics

• Technical Characteristics:

  • Deposit Hardness: 28–35 HRC

  • Impact Resistance: High

  • Abrasion Resistance: Moderate

  • Crack Resistance: Excellent (controlled microstructure minimizes HAZ sensitivity)

  • Machinability: Good (permits post-weld finishing when required)

  • Multi-layer Capability: Yes

  Metallurgical Advantage: The chromium-molybdenum alloy chemistry (Cr: 2.0%, C: 0.25%) creates a deposit matrix that resists brittle failure under shock loading. This distinction is significant—premium hardness without corresponding toughness results in catastrophic fracture rather than controlled wear. The 350 grade solves this through careful alloy design.

  Operational Flexibility: Multi-layer buildup capability permits application to components with complex wear patterns or where cumulative wear depth exceeds single-pass deposition. Post-weld machining is feasible, enabling precise component geometry restoration.

  Welding Parameters: 1.2mm (140–250A) | 1.6mm (180–320A) | DCEP | All positions except vertical down

Ultra Hard Facing 500: High-Performance Hardfacing for Severe Abrasion

Application Profile: Bucket edges and lips, conveyor screws, crusher components, mixing paddles, bulldozer and loader blades

The 500 grade addresses applications dominated by severe, continuous abrasion with moderate impact loading. Operating at 48–55 HRC, it provides substantial hardness advancement over the 350 grade while maintaining sufficient toughness for multi-layer application strategies.

Technical Characteristics

• Deposit Hardness: 48–55 HRC

• Impact Resistance: Moderate

• Abrasion Resistance: High

• Deposition Rate: High (operational efficiency advantage)

• Bead Appearance: Uniform and consistent

• Multi-layer Capability: Yes

Metallurgical Advantage: The chromium-carbide chemistry (Cr: 5.5%, C: 0.45%) establishes a microstructure where hard carbide particles provide primary wear resistance against three-body abrasion and sliding friction. The elevated chromium content increases carbide density compared to lower-grade formulations, translating to measurable wear-resistance improvement in high-volume material handling applications.

Operational Efficiency: The 500 grade deposits at elevated rates, reducing welding time per linear inch and improving fabricator productivity on high-volume hardfacing projects. This economic advantage compounds across large-scale equipment protection initiatives.

Welding Parameters: 1.2mm (160–280A) | 1.6mm (200–340A) | DCEP | All positions except vertical down

Ultra Hard Facing 600: Maximum Wear Resistance for Extreme Industrial Environments

Application Profile: Chutes and hoppers, sinter plant components, coal mining tools, cement kiln components, fan blades, and conveyor flights

The 600 grade represents the upper performance boundary of hardfacing technology. At 58–63 HRC, it approaches tool steel hardness levels and is engineered exclusively for extreme abrasion environments where standard hardfacing proves inadequate.

Technical Characteristics

• Deposit Hardness: 58–63 HRC

• Impact Resistance: Low (optimised for wear resistance; unsuitable for shock-loading applications)

• Abrasion Resistance: Exceptional

• Surface Machinability: Non-machinable (by design)

• Application Strategy: Single-layer only (multi-layer application introduces residual stress and HAZ cracking risk)

Metallurgical Advantage: The high-chromium carbide alloy (Cr: 32.0%, C: 5.2%) produces a ceramic-dominant microstructure where chromium carbide particles dominate the deposit matrix. This composition delivers wear resistance at scales that conventional steel cannot achieve, addressing extreme three-body abrasion, gouging, and grinding wear.

Engineering Trade-Off: The extreme hardness that enables wear protection inherently reduces impact tolerance. The 600 grade is prescribed for applications where abrasion is the singular wear mode and shock loading is absent or minimal.

Single-Layer Requirement: Multi-pass application of the 600 grade introduces significant residual stress concentrations and heat-affected zone degradation, increasing fracture risk. Single-layer deposition remains the prescribed application methodology.

Welding Parameters: 1.2mm (160–280A) | 1.6mm (220–360A) | DCEP | All positions except vertical down

Selection Methodology: Matching Grade to Operating Environment

Primary Wear Mode Assessment

Technical Expertise and Custom Solutions

At Ultramet Welds, we take pride in our technical expertise and customer-first approach. We understand that every industry and application has unique challenges, so we work closely with clients to develop customized hardfacing wire formulations that match their exact requirements.

Our in-house R&D team continuously innovates alloy compositions and production methods to enhance the performance of our hardfacing flux cored wires and solid hardfacing wires. We also provide detailed technical guidance on welding procedures, preheat/post-weld treatments, and parameter optimization to help our customers achieve the best results.

Manufacturing Excellence and Quality Assurance

Quality is the foundation of our success at Ultramet Welds. We follow strict quality control procedures at every stage of manufacturing: from raw material selection to final inspection. Our production facilities are equipped with advanced wire drawing, flux coating, and heat treatment systems to ensure uniformity and precision.

Each batch of hardfacing welding wire and hardfacing flux cored wire undergoes:

• Chemical composition analysis
  
  

• Mechanical testing (tensile strength, hardness, impact)
  
  

• Microstructural examination
  
  

• Welding performance evaluation
  
  

These measures guarantee that our products meet or exceed the expectations of our global clientele.

Choosing Ultramet Welds means choosing reliability, performance, and long-term value. Here’s why customers across industries trust us

Depth of experience in welding consumable manufacturing

Consistent product quality and process traceability

Global supply capabilities and timely delivery

In-depth metallurgical knowledge and technical expertise

Dedicated technical support and after-sales service

Our hardfacing welding wire and hardfacing flux cored wire are used by OEMs, fabricators, and maintenance teams who demand superior wear resistance and dependable performance.

Experience, Expertise, and Trust -The Ultramet Welds Advantage

At Ultramet Welds, our work is guided by the principles of EEAT: Expertise, Experience, Authoritativeness, and Trustworthiness. Our team of engineers, metallurgists, and welding professionals brings decades of hands-on experience in designing and delivering high-performance welding solutions.

We don’t just manufacture wires; we partner with our customers to improve productivity, reliability, and profitability. From product selection to process optimisation, our experts are always available to assist.

Get in Touch with Ultramet Welds

If you’re looking for high-quality hardfacing welding wire or hardfacing flux-cored wire, Ultramet Welds offers the right solution backed by technical expertise and proven results.