50+ years of experience with providing wide area of specialty product services
Duroxite® Roller Wire
Hardfacing Wire, Duroxite® Wear-Resistant Roller Wire, Duroxite® Abrasion-Resistant Roller Wire,Flux-Cored Welding Wire, Duroxite® High-Performance Roller Wire, Duroxite® Chromium Carbide Roller Wire, Overlay Welding Wire, Repair Welding Wire, Duroxite® Toughened Roller Wire, Duroxite® Cement Industry Roller Wire
Duroxite® Roller Wire is a specialized welding consumable designed for hardfacing applications, particularly for wear-resistant protection of roller surfaces in industries like cement, steel, and mining. The weld deposit features abrasion-resistant material made up of a high concentration of very hard M7C3 chromium-rich carbides, typically achieving a hardness of 1700 HK*. These carbides are evenly distributed within a ductile eutectic austenite matrix. In addition to its high chromium content, the wire contains added molybdenum to enhance overlay toughness, strengthen the matrix, and refine carbide size, which boosts abrasion resistance and extends service life. Duroxite® Roller Wire is specifically engineered for restoring worn rollers through stringer bead welding. It is suitable for welding on curved surfaces and allows for multiple layers of deposition up to 75mm (3’’) thick. Preheating, interpass temperature, and post-weld heat treatment should be applied based on the base metal’s specifications. Stress-relief cracks may naturally appear after welding.
*) HK is the Knoop microhardness used primarily for very brittle materials.
Key Benefits
- The same level of wear resistance is guaranteed from the surface down to 75% of the overlay’s depth.
- The optimal alloy formulation creates a carbide composition that delivers an excellent balance of wear resistance and uniform bonding.
- It is possible to weld layers up to 75mm (3’’) thick, allowing for the complete restoration of worn rollers to their original design.
Typical Applications
Duroxite® Roller Wire is primarily designed for repairing roller wear parts operating at temperatures up to 350ºC (660ºF). Common applications include cement vertical mill rollers and coal pulverizer rollers.
Standard Dimensions
| Standard diameter Metric |
|---|
| 2.8 mm |
Mechanical Properties
| ASTM G65 – Procedure A weight loss 2) | Typical weld metal surface hardness 1) | ||
|---|---|---|---|
| Number of overlay passes | Surface (g max) | 75 % depth of overlay 3) (g max) | Hardness: 3-layer deposit on mild steel |
| Multiple passes | 0.18 | 0.18 | 58 – 63 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
| Typical all-weld metal analysis (Weight %) | |||||
|---|---|---|---|---|---|
| C (%) | Mn (%) | Si (%) | Cr (%) | Mo (%) | Fe |
| 4.5 | 0.5 | 0.5 | 27.0 | 0.8 | Balance |
Microstructure
The microstructure of Duroxite® Roller Wire consists of a high percentage of exceptionally hard primary M7C3 chromium-rich carbides, typically achieving a hardness of 1700 HK. These carbides are evenly distributed within a ductile eutectic austenite matrix. The volume fraction of primary carbides is kept between 30% and 50%, ensuring an optimal balance of wear resistance and uniform bonding.
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 |
| 2.8 mm | 300 – 450 | 400 | 28 – 32 | 30 | 15 mm – 30 mm | 25 mm |
Recovery: 90%
Delivery Conditions
| Standard package | Diameter | Weight |
|---|---|---|
| Type | Metric | Metric |
| Drum | 2.8 mm 0.1094 mm | 200 kg |
Fabrication and Other Recommendations
The welded overlay components can be processed through welding, cutting, forming, and machining. For detailed recommendations, refer to the Duroxite® Product brochure or consult your local technical support representative.
Safety precautions
Welding or cutting Duroxite® products generates gases and harmful fumes that are chemically complex and challenging to categorize. The primary toxic component in the fumes is hexavalent chromium. It is recommended to use proper exhaust ventilation systems and fume-extraction torches, along with appropriate protective clothing and respiratory protection for operators.