Hardfacing Flux Cored Wire (58–63 HRC)

ULTRA Extreme Abrasion Hardfacing Wire is a high-alloy chromium carbide hardfacing consumable developed for components exposed to severe and continuous abrasive wear with minimal impact loading. Designed for self-shielded and gas-shielded FCAW processes, this wire produces an extremely hard, non-machinable weld deposit, making it ideal for single-layer hardfacing applications.

This grade represents the highest wear-resistance tier within the ULTRA hardfacing product range and is validated through in-house testing for consistent hardness and performance.

Product Classification & Testing

This product is classified as a hardfacing flux-cored wire suitable for both self-shielded and gas-shielded welding. It produces a very high hardness weld deposit in the range of approximately 58–63 HRC, achieved through a high chromium carbide alloy system.

Due to its carbide-rich structure, this wire is recommended strictly for single-layer application and is not suitable for multi-layer buildup.

Typical Applications

ULTRA Extreme Abrasion Hardfacing Wire is intended for equipment subjected to intense abrasive wear, where erosion and material loss are the primary failure mechanisms.
Typical applications include chutes and hoppers handling bulk materials, sinter plant components, coal mining tools, cement kiln parts, fan blades, and screw conveyors. It is particularly effective in mining, cement, power, and material handling industries where abrasive media is present continuously.

Key Features & Performance Advantages

This hardfacing wire delivers exceptional resistance to extreme abrasion, significantly extending component service life in harsh environments. The high chromium carbide weld deposit forms a dense, wear-resistant surface capable of withstanding aggressive sliding and particle abrasion.
ULTRA Extreme Abrasion Hardfacing Wire produces a smooth, stable arc with good bead appearance, despite its high alloy content. The resulting hardfaced surface is non-machinable, making it ideal for final wear layers where maximum hardness is required.

Weld Metal Chemistry & Wear Structure

The undiluted weld metal chemistry is characterized by very high carbon and chromium content, supported by controlled manganese and silicon levels. This alloy design promotes the formation of primary chromium carbides, which are responsible for the wire’s exceptional abrasion resistance.

The weld deposit exhibits very high abrasion resistance with low impact tolerance, and should be applied only in conditions where impact loading is minimal.

Mechanical & Wear Characteristics

Weld metal deposited using ULTRA Extreme Abrasion Hardfacing Wire typically achieves a hardness of 58–63 HRC, providing maximum resistance to abrasive wear. Impact resistance is low, which is why this wire is best suited for applications dominated by sliding or erosive abrasion rather than shock loading.

Recommended Welding Parameters & Usage Guidelines

The wire is available in 1.2 mm and 1.6 mm diameters, supporting a wide range of amperage settings for industrial hardfacing operations. Welding is performed using DCEP (electrode positive) polarity for stable arc performance.

This wire is recommended only for single-layer deposition. Applying multiple layers can increase the risk of cracking due to the extremely hard and brittle nature of the weld metal. When using mixed shielding gases, operating at 1–2 volts lower is advised to maintain arc stability and bead control.

Packaging & Storage

ULTRA Extreme Abrasion Hardfacing Wire is supplied in 15 kg vacuum-sealed packs, precision wound on durable plastic spools. Vacuum packaging protects the wire from moisture and contamination, ensuring consistent feeding and weld quality.

Why Choose ULTRA Extreme Abrasion Hardfacing Wire

ULTRA Extreme Abrasion Hardfacing Wire is engineered for industries where abrasion is severe, continuous, and unavoidable. As the top-end solution in the ULTRA hardfacing lineup, it complements lower-hardness grades by offering a targeted solution for the most demanding wear environments.

For cement plants, mining operations, sinter plants, and bulk material handling systems, this wire delivers maximum abrasion resistance where component life directly impacts operational efficiency and cost.

ULTRA HARD FACING 600

Hardfacing Wire for Extreme Abrasion Resistance

• Chutes & hoppers

• Sinter plant parts

• Coal mining tools

• Cement kiln components

• Fan blades, Screw conveyors

Typical Applications

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Key Features

• Exceptional resistance to extreme abrasion

• Non-machinable surface

• High chromium carbide alloy

• Smooth arc with good bead appearance

• Ideal for single layer hardfacing

HARD FACING WIRE