Hardfacing Machine

At Deewi Automation, we are committed to bringing revolutionary progress to the industrial manufacturing field through high-end plasma cladding technology. Our range of plasma cladding machines represents our latest achievements in precision manufacturing and innovative solutions designed to meet your highest requirements for efficiency, precision and reliability.

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Innovative technology, excellent performance.

Our plasma cladding machines use the most advanced technology to provide uniform and precise coverage on a variety of metal surfaces, significantly improving the wear resistance, corrosion resistance and service life of the workpiece. Whether it’s complex industrial components or precision manufacturing needs, Deewi’s welding machines provide unparalleled solutions.

Types of Hardfacing Machines:

Based on the type of heat source used, they can be divided into:
- Laser Cladding Machines: These use high-energy lasers as the heat source and can precisely control the welding speed and intensity, achieving high-precision and high-quality welding results. The equipment is relatively expensive and is commonly used where high precision and batch production are required.
- Plasma Transferred Arc Welding Machines: Using a plasma arc as the heat source, they can also control the welding speed, current, and voltage precisely for high-quality welds. The equipment is cost-effective and flexible to use. Plasma arcs have high energy density and are commonly used for high-energy welding applications, such as repairing workpieces with high hardness and high melting points.
Based on the degree of automation, they can be classified into:
- Automated Hardfacing Machines: These feature automated control systems and welding robots or mechanical arms that can precisely control welding speed, current, voltage, and path. They offer good welding precision and consistency, low labor costs, and are suitable for large-volume, standardized hardfacing tasks.
- Manual Hardfacing Machines: These belong to the traditional hardfacing methods, where welding quality heavily depends on the operator’s skill and experience. They are less consistent than automated welding but are very cost-effective and flexible in use.
Based on equipment size and application scenario, they can be categorized into:
- Large Hardfacing Machines: Mostly used for batch production and repair, generally highly automated with high welding efficiency, and low reliance on labor. Suitable for large enterprises engaged in batch welding operations.
- Mobile Hardfacing Machines: Commonly seen with small to medium-sized equipment, featuring a mobile design for easy transport and movement, offering greater flexibility, though with limited automation and stability.
- Portable Hardfacing Machines: Compact design, simple in structure, extremely convenient for on-site repairs, allowing for in-situ repairs without disassembly. Often used for on-site repair work of machinery and equipment parts.

The above are only a few of the commonly seen machine types and not an exhaustive list.

Applications and Usage Scenarios of Hardfacing Machines:

Repair and Maintenance: Hardfacing can repair worn parts, restoring their original size and shape. For example, the production and repair of parts like bucket teeth, blades, bearing housings, bearings, hydraulic cylinders, piston rods, gears, racks, rotating shafts, and couplings in construction machinery.
Adding Wear-Resistant Layers: Adding wear-resistant layers to the surface of newly manufactured workpieces can reduce material costs and extend their service life, such as applying hardfacing materials to the hammers and blades of mining machinery.
Enhancing Impact Resistance: For parts that need to withstand strong impacts, like hammerheads and crusher arms, hardfacing can improve their impact resistance.
Extending Service Life: For consumable parts, such as metal rollers and wheels in conveyor systems, hardfacing can significantly enhance their wear resistance and service life.
Imparting Special Properties: For parts requiring corrosion resistance, high-temperature resistance, or other special properties, selecting the appropriate hardfacing material can endow the workpiece with the needed characteristics.

Hardfacing Machines are extremely widely used across various industries and, with the continuous development of new processes and technologies, are replacing traditional processes in many fields. They improve the reliability, safety, and economy of equipment, reducing costs and energy consumption, and are becoming an indispensable tool in modern industry.

Quick Q&A – About Hardfacing Machine.

When using or maintaining Hardfacing Machines, users often encounter a range of issues. Below are some common questions and their corresponding answers:

A1: The selection of suitable welding material should consider:

Working conditions: Temperature, friction, impact, corrosion, etc.
Chemical composition and heat treatment state of the base material: To ensure compatibility between the hardfacing layer and the base material.
Performance requirements of the hardfacing layer: Hardness, toughness, wear resistance, etc.

A2: When choosing a hardfacing machine, consider the following criteria:

Workpiece material and size: Different workpiece materials and sizes may require different types of hardfacing machines.
Required hardfacing material: Different hardfacing materials (like high-chromium cast iron, tungsten carbide alloys, etc.) have different welding requirements.
Production efficiency: Choose the degree of automation based on production volume, whether automatic or semi-automatic.
Complexity of the workpiece: For complex pieces, to ensure welding precision, equipment with higher intelligence and flexibility is necessary.
Budget and cost-effectiveness: Consider the initial and operational costs of the equipment, selecting a cost-effective supplier. Deewi Automation is your best choice.
Supplier professionalism and after-sales service: This is crucial when making a choice. Often we’re unable to judge this aspect immediately, and you’ll need to compare and try out different options. Deewi Automation has extensive experience and technical reserves in the field of Hardfacing Machines, providing the most professional after-sales service, making us your best choice.

A3: Post-hardfacing, the workpieces may require further treatment, including:

Stress-relief annealing: To reduce welding stress.
Mechanical machining: Such as grinding or cutting to achieve final dimensions and surface roughness.
Heat treatment: To improve the performance of the weld zone.

A4: Methods to control heat input include:

Adjusting welding parameters: Current, voltage, welding speed, etc.
Using proper cooling methods: Intermittent welding or using coolants to reduce temperature.
Welding technique selection: For situations that require precise heat control, pulse hardfacing can be used to minimize heat input.

A5: Maintenance of hardfacing equipment mainly includes:

Regular cleaning: Remove dust and welding residue regularly, check for blockages in nozzles or pipes.
Checking electrical systems and conveyance lines: Regularly inspect for loose or leaking connections, check for aging or cracking in hoses and pipes.
Mechanical part maintenance: Regularly lubricate moving parts and check for wear to ensure precise and stable movement.
Software updates: For automated equipment, the safety and reliability of software are equally important. Ensure that the software of our machines is stable and up-to-date.

A6: Safety requirements for operators include:

Personal protective equipment: Such as safety goggles, earplugs, welding gloves, and protective clothing.
Ventilation: Ensure adequate ventilation to remove harmful fumes.
Training and guidance: Regular safety and operational training are essential to ensure operators understand how to use the equipment and safety measures.

A7: Methods to solve cracking problems may include:

Preheating: Preheat the workpiece before welding to reduce thermal stress during the process.
Using low-hydrogen welding materials: These can reduce hydrogen content in the weld area, thus minimizing hydrogen-induced cracking.
Controlling welding speed and heat input: Adjust welding parameters to prevent local overheating and cracking.
Post-weld heat treatment: Carry out suitable post-weld heat treatment, like annealing or normalizing, to eliminate or alleviate residual stress-induced cracking.
Changing welding sequence: Reasonably arranging the welding sequence of different parts of the workpiece can balance thermal stress and reduce cracking.

A8: For common faults in hardfacing equipment, here are some suggested solutions:

Unstable welding current or voltage: Check the power supply and other connections, as well as the correctness of welding parameter settings.
Wire jamming: Clean or replace the wire conduit, check and adjust the pressure of the wire feed rollers.
Torch blockage: Regularly clean the inside of the torch, especially the nozzle and contact tip.
Unstable equipment operation: Check all mechanical parts for tightness and lubrication, as well as signs of severe wear.

A9: Methods to determine the quality of the hardfacing layer include:

Visual Inspection: Check if the weld is uniform and look for any signs of cracking or porosity.
Hardness Test: Measure the hardness of the hardfacing layer using a hardness tester.
Metallographic Analysis: Examine the microstructure of the hardfacing layer to assess its structural composition, uniformity, and any potential defects.
Wear Resistance Test: Evaluate the wear resistance through tests either in a laboratory setting or under actual working conditions.
Non-Destructive Testing (NDT): Employ techniques such as X-ray or ultrasonic testing to check for internal cracks and voids within the hardfacing layer.
Corrosion Resistance Test: For applications requiring corrosion resistance, perform tests such as the salt spray test to evaluate the layer’s ability to withstand corrosive environments.

A10: To prevent distortion:

Use proper fixture and clamping techniques to minimize movement during welding.
Control heat input: Use lower heat settings, pulsed welding, or other techniques to minimize the heat affected zone.
Sequence welding: Plan the welding sequence to distribute heat evenly and avoid concentration in one area.
Employ preheat and interpass temperature control: This can minimize thermal stresses that lead to distortion.

A11: For handling uneven surfaces:

Mechanical Processing: Surface irregularities can be smoothed out through mechanical methods such as grinding or milling.
Secondary Hardfacing: If the unevenness is substantial, a second hardfacing operation might be necessary to fill in the recessed areas.