CLADDING TECHNOLOGY SHANXI CO., LTDPowder-Adding Cladding Process and Application of Wear-Resistant Cladding Composite Steel Plate
Literature Overview
This paper, published in Welding Technology (焊接技术) in 1996 by Meng Zhaohong, Yan Zhixing, and Wang Shangxian from the Chinese Academy of Agricultural Mechanization Sciences, represents an early and pioneering contribution to the field of powder-adding cladding technology for wear-resistant composite steel plates. The publication date places this work at the forefront of domestic Chinese research in advanced welding cladding processes, predating many subsequent studies on powder-adding techniques by several decades.
Core Technical Content
Powder-adding cladding is a hybrid welding process in which metal powder is fed into the welding arc or molten pool during the welding operation, allowing for the deposition of materials with compositions different from the base electrode or wire. This technique combines the advantages of conventional arc welding (high deposition rates, good fusion) with the compositional flexibility of powder-based processes.
Process Configuration and Parameters
The powder-adding cladding process typically employs a submerged arc welding (SAW) or gas metal arc welding (GMAW) configuration with an external powder feeder that introduces alloy powder into the arc zone.
| Process Parameter | Typical Range | Function |
|---|---|---|
| Welding Current | 300–600 A (SAW) / 200–400 A (GMAW) | Provides heat input for melting |
| Arc Voltage | 25–35 V (SAW) / 22–30 V (GMAW) | Controls arc length and pool geometry |
| Powder Feed Rate | 100–400 g/min | Determines alloy addition rate |
| Travel Speed | 0.3–1.0 m/min | Controls deposition rate and cooling rate |
| Powder Composition | High-Cr, high-C, or Ni-based alloys | Determines cladding layer properties |
| Substrate Material | Q235, Q345 carbon/low-alloy steel | Structural base material |
Wear-Resistant Cladding Layer Composition
The wear-resistant cladding layers produced by powder-adding processes typically incorporate high levels of chromium (20–40%), carbon (2–5%), and may include additional alloying elements such as molybdenum, vanadium, and tungsten. These compositions promote the formation of hard carbide phases including M7C3, M2C, and M6C that provide excellent abrasion resistance.
| Cladding Layer Type | Typical Composition (wt%) | Hardness (HV) | Wear Resistance Index |
|---|---|---|---|
| High-Cr Iron-based | Cr 25–35, C 3–5 | 600–800 | High |
| High-Cr-Ni Iron-based | Cr 20–30, Ni 10–20, C 3–5 | 550–750 | High with corrosion resistance |
| High-C High-Cr | C 4–6, Cr 15–25 | 700–900 | Very high |
| Ni-based with WC | Ni 55–65, Cr 20–30, W 10–15 | 800–1100 | Excellent |
Engineering Practice Implications
The application of powder-adding cladding to composite steel plates represents a cost-effective approach to producing wear-resistant surfaces on structural components. Unlike solid overlay plates or explosive cladding, powder-adding cladding allows for the production of composite plates with varying cladding thicknesses and compositions without the need for expensive consumable overlay materials.
Agricultural Machinery Applications
The involvement of the Chinese Academy of Agricultural Mechanization Sciences indicates that the primary application target was agricultural machinery components such as plowshares, harrow teeth, seed drill parts, and combine harvester components. These components are subjected to severe abrasive wear from soil, rocks, and plant material, and the wear-resistant cladding significantly extends their service life.
Comparison with Alternative Cladding Methods
| Method | Deposition Rate | Dilution | Cost | Thickness Range | Application |
|---|---|---|---|---|---|
| Powder-adding SAW | High (10–30 kg/h) | Moderate (15–30%) | Low | 1–10 mm | Large-area cladding |
| Powder-adding GMAW | Medium (5–15 kg/h) | Low–Moderate (10–25%) | Medium | 0.5–5 mm | Medium-area cladding |
| Strip cladding | Very high | Low (5–15%) | High (strip cost) | 0.5–3 mm | Precision cladding |
| Explosive cladding | Very high | None | Very high | 0.5–5 mm | Bimetal plates |
Quality Control and Testing
Quality assurance for powder-adding cladded composite steel plates requires verification of several critical properties. The bond strength between the cladding layer and the substrate must be confirmed through shear or tensile bond testing per relevant standards. The hardness profile across the cladding thickness should be measured to ensure uniform properties. Non-destructive testing including magnetic particle testing (MT) for surface cracks and ultrasonic testing (UT) for subsurface defects is essential for detecting process-induced defects.
Study Insights and Reflections
This 1996 publication represents an important milestone in the development of powder-adding cladding technology in China, demonstrating the early recognition of this technique's potential for producing cost-effective wear-resistant components. The research by the Chinese Academy of Agricultural Mechanization Sciences highlights the practical, application-driven nature of the work, which sought to extend the service life of agricultural machinery components through advanced surface engineering. The findings and process development described in this paper laid the groundwork for subsequent research on powder-adding cladding that has continued to evolve over the past three decades. For contemporary engineers, this early work serves as a reminder of the foundational contributions that have shaped the current state of cladding technology and underscores the enduring importance of process innovation in addressing real-world engineering challenges.