Duroxite® 300 Wire

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General Product Description

Duroxite® 300 Wire is a flux-cored welding wire for hardfacing components subject to extremely severe sliding wear applications using an open-arc or gas shielded arc welding processes. The weld deposit of Duroxite® 300 Wire consists of specially formulated abrasive materials employing a uniform glass-forming melt chemistry that allows high undercooling to be achieved. Duroxite® 300 weld overlay contains a unique high volume of ultra-fine tungsten-niobium-molybdenum-rich complex borocarbide phase with a grain size refined down to 500 nm. The borocarbides are completely wetted in a ductile matrix preventing premature pull-out delamination, crack nucleation and bridging. This results in a product with significantly improved service life that maintains high toughness in severe sliding wear applications.

Duroxite® 300 Wire is suitable for single or double-layer deposit with both stringer and oscillation beads. It naturally reveals stress-relief cracks after welding. Preheating, inter-pass temperature, and post-weld heat treatment are as needed according to the base metal recommendations. If welding fume generation is a concern, a gas shielded arc welding process is recommended. A slight drag angle is preferred for better performance while welding. If welding with downhill or uphill positions, reduced wire feed speed and voltage are preferred. Duroxite® 300 Wire is designed to weld on carbon steel or low alloy steel substrates experiencing severe wear for both dry and wet (slurry) abrasive environments at ambient or elevated temperatures up to 600°C (1100°F). Duroxite® 300 Wire is not compatible with austenitic alloys. Duroxite® 300 Wire is an excellent alternative to tungsten carbide hardfacing wire.

Key Benefits

  • Extreme wear resistance in dry and wet abrasive environments with a high degree of toughness.
  • Cost effective alternative to tungsten carbide wire with equivalent service life and better impact resistance.
  • Maintains a consistent wear resistance from surface down to 75% of the overlay.
  • Has uniform through-thickness hardness of 67 to 70 HRC for single and double-layer overlay.
  • Thinner thickness overlay applied compared to traditional chromium carbide overlay (CCO) or complex carbide overlay which result in a lighter weight product while increasing service life.

Typical Applications

Duroxite® 300 Wire is mainly designed to use for hardfacing any steel substrates (not compatible with austenitic alloys) undergoing extremely severe wear in mining, power generation, cement, oil sand, steel production, waste handling, and pulp and paper industries. Typical examples include:

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    Mining Crusher rolls, Skip liners, Slurry pipes, Slurry pumps, Conveyor chains, Excavator bucket liners
    Cement Fan blades, Deflector blades, Cranker crushers
    Oil sands Surge bins, Feed chutes, Slurry pipes, Slurry pumps
    Steel Ore chutes
    Power Screw augers, Wear liner plates, Ash handling equipment liners
    Agriculture Grain shredding hammers, Sugar mill knives, Row crop sweeps
    Oil and Gas Fracking blender pumps
    Construction Snow plow shoes, Demolition tools
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      Mining
      Crusher rolls, Skip liners, Slurry pipes, Slurry pumps, Conveyor chains, Excavator bucket liners
      Cement
      Fan blades, Deflector blades, Cranker crushers
      Oil sands
      Surge bins, Feed chutes, Slurry pipes, Slurry pumps
      Steel
      Ore chutes
      Power
      Screw augers, Wear liner plates, Ash handling equipment liners
      Agriculture
      Grain shredding hammers, Sugar mill knives, Row crop sweeps
      Oil and Gas
      Fracking blender pumps
      Construction
      Snow plow shoes, Demolition tools

      Standard Dimensions

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        Standard diameter
        Metric
        1.6 mm
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          Standard diameter
          Metric
          1.6 mm

          Mechanical Properties

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            ASTM G65 – Procedure A weight loss 2)
            Typical weld metal surface hardness
            Slurry jet erosion weight loss 4)
            Number of overlay passes Surface
            (g max)
            75 % depth of overlay 3)
            (g max)
            Weld deposit on mild steel 1)
            (HRC)
            20o Impingement angle
            (g typical)
            45o Impingement angle
            (g typical)
            Single pass 0.10 0.10 67 - 70 0.0329 0.0591
            Double passes 0.10 0.10 67 - 70 0.0329 0.0591
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              1) Surface hardness is measured on machined flat surface just below overlay surface.

              2) ASTM G65 is a standard test measuring sliding abrasion resistance using a dry sand/rubber wheel apparatus. ASTM G65-Procedure A is the most severe test method.

              3) ASTM G65 wear test is conducted at 75% depth of the overlay materials to ensure consistently good wear resistance from the top surface through to the depth of 75% of the overlay.

              4) Duroxite 300 outperforms typical CCO in an SJE test. Typical CCO loses 0.0689 g at 20° and 0.0995 g at 45° impingement angles in the same test. For more information about Duroxite® 300 and its performance in a Slurry Jet Erosion Test, please see the Duroxite® Brochure – The Latest in Overlay Technology available at ssab.com.

              Test results for mechanical properties

              Test results for mechanical properties, deposit overlay chemical composition, surface hardness, and ASTM G65-A weight loss were obtained from a weld produced and tested according to prescribed standards, and should not be assumed to be the expected results in a particular application or weldment. Actual results will vary depending on many factors, including, but not limited to, weld procedure, substrate chemistry and working temperature, weldment design and fabrication methods. Users are cautioned to confirm by qualification testing, or other appropriate means, the suitability of any welding consumable and procedure before use in the intended applications.

              Chemical Composition

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                Typical weld deposit chemical composition (wt. %)
                C Mn Si Cr W B Mo Nb Al Fe
                < 5.0 < 5.0 < 2.0 < 20.0 < 10.0 < 5.0 < 10.0 < 10.0 < 5.0 Balance
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                  Welding recommendations

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                    Welding conditions
                    Current type Shielding gas Welding positions
                    DCEP (Direct current electrode positive) Open arc (no shielding) Flat, horizontal, half up, half down
                    DCEP (Direct current electrode positive) 75% Ar / 25% CO2
                    98% Ar / 2% O2
                    Flat, horizontal, half up, half down
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                      Welding parameters recommendations

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                        Shielding Diameter Amperage (A) Voltage (V) Wire feed speed Stick-out
                        Open arc (no shielding) 1.6 mm0.06250 mm 220 24 - 25 7.0 m/min 25 mm
                        Gas shielded 1.6 mm0.06250 mm 220 24 - 25 7.0 m/min 20 mm
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                          Recovery: 90%

                          Delivery Conditions

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                            Standard package
                            Diameter
                            Weight
                            Type Metric Metric
                            Spool 1.6 mm0.06250 mm 15 kg
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                              Fabrication and Other Recommendations

                              The welded overlay components can be processed by welding, cutting, forming and machining. Specific recommendations can be found in the Duroxite® Product brochure or by consulting your local technical support representative.

                              Safety precautions

                              When welding or cutting Duroxite® products, gases and harmful fumes are produced that are chemically complex and difficult to classify. The major toxic component in the fumes is hexavalent chromium. The proper exhaust ventilation equipment and fume-extraction torches are recommended, as well as suitable protective clothing and respiratory protection for operators.