Duroxite® 100 Wire
Hardfacing Wire, Wear Resistant Wire, Welding Wire, Abrasion-Resistant Wire, Hardfacing Welding Wire, Wear Protection Wire, High-Performance Wire, Wire for Tough Applications, Composite Welding Wire
Duroxite® 100 Wire is a flux-cored welding wire specifically engineered for hardfacing applications where components face intense sliding wear and moderate to low impact. It is used in open-arc welding processes to apply a wear-resistant layer to parts requiring abrasion protection. The weld deposit includes abrasion-resistant materials with a high concentration of extremely hard M7C3 chromium-rich carbides. These carbides, typically having a hardness of 1700 HK *), are uniformly distributed within a ductile eutectic austenite matrix. Stress-relief cracks may naturally appear after welding.
Welding Filler Wire, Wear Parts Wire, Durable Welding Wire, Abrasion-Resistant Welding Wire, Wire for Mining Equipment, Wire for Extreme Conditions
Duroxite® 100 Wire is ideal for single-layer or multi-layer deposits, with a maximum of three layers. Preheating, interpass temperature, and post-weld heat treatment should be applied as per the base metal’s guidelines. When welding in downhill or uphill positions, it is recommended to reduce the wire feed speed and voltage.
*) HK is the Knoop microhardness used primarily for very brittle materials.
Key Benefits
- The same level of wear resistance is maintained from the surface to 75% of the overlay depth in multi-layer deposits.
- The optimal alloy formulation creates a carbide composition that ensures an excellent balance of wear resistance and uniform bonding.
Typical Applications
Duroxite® 100 Wire is primarily designed for hardfacing wear parts exposed to abrasion from earth, sand, and other abrasives up to 350ºC (660ºF). Common applications include crusher hammers, gyratory crusher cones and mantles, dredging pumps, slurry pipes, dragline bucket liners, coal pulverizer rolls, coke hammers, sand dredging components, mining and earthmoving machinery, and sorting screens.
Standard Dimensions
| Standard diameter Metric |
|---|
| 1.2 mm |
| 1.6 mm |
| 2.8 mm |
Mechanical Properties
| ASTM G65 – Procedure A weight loss 2) | Typical all-weld metal surface hardness 1) | ||||
|---|---|---|---|---|---|
| Number of overlay passes | Classifications | Surface (g max) | 75% depth of overlay 3) (g max) | Hardness: 2-layer deposit on mild steel | Hardness: 3-layer deposit on mild steel |
| Multiple passes | DIN 14700 T Fe15 g DIN 8555 MF 10 GF 60 G |
0.18 | 0.18 | 58 – 65 HRC | 60 – 65 HRC |
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.
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
| Standard diameter | Typical all-weld metal analysis (Weight %) | ||||
|---|---|---|---|---|---|
| Metric | C (%) | Mn (%) | Si (%) | Cr (%) | Fe |
| 1.2 mm (0.04688 mm 0.045″) | 4.7 | 0.2 | 0.6 | 27 | Balance |
| 1.6 mm (0.06250 mm) | 5.5 | 0.2 | 0.6 | 29 | Balance |
| 2.8 mm (0.1094 mm) | 5.5 | 0.2 | 0.6 | 29 | Balance |
Welding recommendations
| Welding conditions | ||
|---|---|---|
| Current type | Shielding gas | Welding positions |
| DCEP (Direct current electrode positive) | None (Self-shielded) | Flat, half up, half down |
Welding parameters recommendations
| Diameter | Amperage (A) | Voltage (V) | Stick-out | |||
|---|---|---|---|---|---|---|
| Metric | Range | Optimum | Range | Optimum | Range | Optimum |
| 1.2 mm | 110 – 250 | 190 | 24 – 30 | 28 | 20 mm – 45 mm | 25 mm |
| 1.6 mm | 150 – 270 | 200 | 25 – 30 | 28 | 20 mm – 45 mm | 25 mm |
| 2.8 mm | 250 – 450 | 300 | 28 – 32 | 30 | 20 mm – 45 mm | 25 mm |
Delivery Conditions
| Standard package | Diameter | Weight |
|---|---|---|
| Type | Metric | Metric |
| Spool | 1.2 mm | 15 kg |
| Spool | 1.6 mm | 15 kg |
| Spool | 2.8 mm | 25 kg |