Cobalt based alloy PTA hardfacing on

different substrate steels

A. E. Yaedu1 and A. S. C. M. DOliveira*1

Published by Maney Publishing (c) IOM Communications Ltd

Components from equipment for different processing industries are exposed to severe service
conditions. Parts are therefore manufactured so that specific demands can be met through
adequate selection of surface processing techniques and hardfacing alloys. Whenever surface
welding techniques are used to improve a components performance, quality requirements such
as controlled dilution of the deposited alloy by the substrate are a priority. This work has evaluated
this interaction between a hardfacing Co based alloy and the substrate steel. A high carbon
cobalt based alloy was plasma transferred arc (PTA) deposited on three different substrate
steels. The role of the chemical composition of the substrate on the characteristics of the coatings
was evaluated for two sets of processing parameters, targeting two extreme dilution levels.
Coatings characterisation was assessed through microstructure analysis, microhardness
measurements, dilution levels, and wear rate measurements. Results showed that the influence
of the substrate chemical composition was more significant for coatings of controlled low dilution
deposits. The selection of the substrate steel affected dilution levels, microstructure, hardness
values, and sliding wear rates exhibited by the coatings. On both sets of coatings deposits made
on carbon steel gave better wear performance than those deposited on the stainless steels
tested.
Keywords: Co alloys, Hardfacing, Dilution, Microstructure, Superalloys, Wear performance

Introduction

Components from equipments of processing industries

frequently operate under severe conditions of wear and/
or temperature. As higher productivity rates are
imposed, components are exposed to harder operating
conditions. In order to avoid increasingly higher
production costs and to extend service life, parts are
manufactured so that selective properties can be
obtained where required. Hardfacing with high performance materials, such as superalloys, is a solution to
processing such components. Sliding valves in fluid
catalytic cracking units (FCC) in oil refinery plants are
an example of components that are hardfaced with high
performance alloys as they are exposed to severe wear
conditions and elevated temperature (700uC). Under
these conditions, good performance has been achieved
by coating parts with Co based alloys. Among Co alloys,
high carbon alloys are indicated for elevated temperature and/or wear resistance.14 These alloys are solid
solution and carbide hardened. The amount of carbon
determines the volume fraction of carbides in the alloy,
and as a consequence, its wear properties.5 However,
due to the presence of carbides, these alloys are not easy
to weld, exhibiting high cracking susceptibility. These
1

Mechanical Engineering Department/Federal University of Paranal, Brazil

*Corresponding author, email sofmat@ufpr.br

2005 Institute of Materials, Minerals and Mining

Published by Maney on behalf of the Institute
Received 27 April 2004; accepted 1 December 2004
DOI 10.1179/174328405X36511

difficulties can be minimised by using adequate processing parameters. Typically these are determined for the
alloy being deposited, regardless of the chemical
composition of the substrate metal. However, taking
into consideration that one of the quality requirements
of surface welded coatings is a controlled dilution of the
deposited alloy by the substrate metal, and that coatings
produced by conventional welding processes exhibit
dilution levels above 20%,5 the chemical composition of
the latter is relevant to maximising coatings performance. In order to evaluate the role of the chemical
composition of the substrate steel on the features of a
surface welded coating, a high carbon cobalt alloy was
deposited on three different steels. The Co based alloy is
commercially known as Stellite 1, and in spite of its wide
use, there is no agreement regarding the microstructure
that coatings exhibit. Classified as a hypereutectic alloy,6
the processing technique and processing parameters for
a given technique determine its final microstructure.7
This discussion has been enriched by the work of Frenk
and Kurz,8 who developed a pseudobinary phase
diagram c-Co/M7C3, Fig. 1. This diagram suggests that
a eutectic reaction occurs at y2?6%C. The alloy used in
this study has 2?53%C, and as a consequence of its
dilution with the substrate material during surface
welding, it will be exposed to chemical composition
fluctuations. One should, therefore, expect that a change
in the chemical composition of the substrate material

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Yaedu and DOliveira

Co based alloy PTA hardfacing on different substrate steels

1 Pseudo binary phase diagram, c-Co/M7C3

feed rate and preheating of the substrate steel, aiming to

obtain high dilution levels of the coating alloy by the
substrate steels. For set 2, a high feed rate was used,
without preheating, focusing on a controlled dilution.
Coated specimens were first evaluated for the presence
of cracks and coating dimensions. For each processing
condition, deposits were sectioned at three different
locations, for dilution evaluation. Dilution levels were
assessed through two different procedures: area relationship (Fig. 2) using quantitative metallographic analysis
to identify the total melted area (coating and substrate
melt pool) and substrate melted area on the transverse
section of coated specimens. Because of the generally
low dilution levels involved in PTA deposits, and due to
the eventual changes of melt pool geometry, the usual
area ratio procedure might be unsuitable and so an
analytical method was also used. The polished transverse sections of coated specimens were submitted to

will cause composition fluctuations of the coating alloy,

and as a consequence, its microstructure.
The aim of this work is to evaluate how the substrate
material can enhance or compromise the performance of
coated parts, in spite of the original properties of the
alloy being deposited. Therefore, as surface performance
is dependent on microstructural features of the coating,
maximisation of the former requires adequate control of
the latter. A set of selected parameters (dilution level,
microstructure, microhardness, and wear rate) was used
to evaluate coating features as a function of the
substrate steel. In order to minimise the effect of
processing technique, plasma transferred arc (PTA)
surface welding was used, this process being known for
the high quality reliable deposits produced.912

Experimental procedures
To study the influence of the chemical composition of
the substrate steel on the characteristics of coatings,
three
different
steels
were
selected.
Plates,
1506100612 mm, of AISI 1020 carbon steel, AISI
304 austenitic stainless steel, and AISI 410 martensitic
stainless steel, were PTA hardfaced with a high carbon
cobalt superalloy, recognised for superior wear performance. Chemical compositions of the as received
materials are shown in Table 1.
The work done by Hallen et al.11 has demonstrated
that dilution levels are a consequence of the processing
parameters used. Therefore, the interaction of the
different substrate steels with the coatings was evaluated
using two sets of processing parameters (Table 2)
targeting two extreme dilution levels. Set 1 used a low

Table 2 Processing parameters used

Processing parameter

Set 1

Set 2

Plasma gas flow argon

Protection gas flow argon
Transport gas flow - argon
Current intensity
Tension
Powder feed rate
Welding rate
Preheating temperature
AISI 1020
AISI 304
AISI 410

5.0 l min1
5?0 l min1
9?0 l min1
1
5?0 l min
8?5 l min1
100110 A
105115 A
30 V
33 V
38 g min1
22 g min1
225 mm min1
170uC
170uC
260uC

Table 1 Chemical composition of as received materials

Co alloy
AISI 1020
AISI 304
AISI 410

460

Co

Fe

Cr

Ni

Mo

Si

Mn

Bal.

3.0
Bal.
Bal.
Bal.

2.5
0.208
0.088
0.098

31.0
0.122
17.58
12.90

3.0
0.089
9.230
0.538

12.5
...
0.063

1.0
0.023
0.337
0.104

2.0
0.103
0.569
0.745

1.0
0.658
1.510
0.832

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Yaedu and DOliveira

2 Areas relationship used to determine dilution levels5

energy dispersive spectroscopy (EDS) semiquantitative

analysis for the iron content, in a scanning electron
microscope. The beam was rastered near the external
surface of the coatings. Dilution levels for each coating
were determined taking into consideration the Fe
content in each substrate according to the ratio
Fe content in the coating
|100
Fe content in the substrate steel
Coatings were also sectioned for metallographic examination on the transverse section of the deposits. These
sections were ground and polished to a 1 mm diamond
finish. Optical and scanning electron microscopy were
used to evaluate the microstructures revealed by etching
with a solution of 15 mL H2O, 15 mL HNO3, 15mL
CH3COOH and 60 mL HCl.

Published by Maney Publishing (c) IOM Communications Ltd

Dilution (%)~

Co based alloy PTA hardfacing on different substrate steels

Vickers microhardness profiles under a load of 500 g

were determined on the transverse sections of the
coatings, starting at 125 mm from the external surface
at 250 mm intervals. Wear performance was assessed by
pin on disc tests, following ASTM G99 standard.
Cylindrical pins of 3 mm diameter were machined from
the coatings by an electrodischarge method to avoid
damaging the coatings. These pins were worn against a
rotating disc of VC131 steel, quenched and tempered
(52HRC). A sliding distance of 2 km and a tangential
velocity of 2 m s1 were kept constant in all tests;
different loads ranging from 0?5 kg to 5 kg were used.
The influence of processing parameters and chemical
composition of the substrate and consequent coating
features on the wear rate of the coatings were evaluated
as a function of the applied load. For each load,
measurements were averaged for five pins, which were
weighed before and after each test for mass loss
evaluation. Wear rate was determined following the
Archard equation13
 
Dm
r

:V
Dx:H
where Q is wear rate (mm3 s21), Dm is mass loss (mg), Dx
is sliding distance (mm), H is surface hardness, and V is
tangential velocity (mm s21).
Q~

a, c, e low feed rate, preheating; b, d, f high feed rate, no preheating; a, b AISI 1020; c, d AISI 304; e, f AISI 410
3 General view of transverse cross-section of coatings deposited on different substrate steels

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Yaedu and DOliveira

Co based alloy PTA hardfacing on different substrate steels

4 Dilution levels evaluated by areas ratio procedure

5 Dilution levels evaluated by iron content ratio

Published by Maney Publishing (c) IOM Communications Ltd

Results and discussion

This work made a first assessment of the role of chemical
composition of the substrate steel in the features of a Co
based alloy coating. It aimed to identify significant
alterations in the coatings and/or their performance that
could be attributed to changes in the chemical composition of the substrate. For this, two extreme processing
conditions were used to obtain different dilution levels in
the two sets of deposits, each of which used three
different substrate steels. Results can be compared
between sets for the role of processing parameters and
within each set for the effect of chemical composition of
the substrate steel. Deposits were first evaluated for their
soundness and dilution levels. Microstructure analysis
and microhardness profiles contributed to characterising
each coating and wear behaviour to classify the influence of
substrate chemical composition on coating performance.

Deposit soundness
A general view of the transverse cross-section of a
coated specimen is shown in Fig. 3. Deposits of 2 mm
and 5 mm thickness were processed for specimen set 1
(preheating and low feed rate) and specimen set 2 (no
preheating and high feed rate). No evidence of lack of
fusion was observed on specimens from both sets.
Transverse cracking was found in the majority of the
deposits and occurred during cooling. This crack
susceptibility has been related to the presence of primary
carbides and to the composition of the Co rich matrix as

Materials Science and Technology

Dilution
Dilution measurements in the form of area ratios are
presented in Fig. 4. Regarding the influence of processing parameters, the effect of the absence of preheating
and increasing powder feed rate on the reduction of
dilution levels, is obvious for the three substrate steels
evaluated. This observation confirmed literature results,
which state an approximately linear relationship
between dilution and preheating temperature over the
range 0300uC.15
For the thicker deposits (higher feed rate) it was
observed that dilution of the Co alloy with the substrate
tended to reduce in the order martensitic stainless steel,
to austenitic stainless steel, to carbon steel. A lower
dilution for carbon steel substrate was also observed for
the other set of deposits, however, martensitic and
austenitic stainless steels presented similar dilution
levels, with the coatings deposited on the latter substrate

a general view; b detailed image of carbides

6 Microstructure of as received atomised Co alloy

462

it affects its toughness.14 Although preheating tends to

reduce the number of cracks, it was observed on both
specimen sets that deposits made on carbon steel and
austenitic stainless steel substrates resulted in fewer
cracks compared to martensitic stainless steel substrate.
For the processing parameters used, crackfree coatings
were produced on carbon steel substrates in the absence
of preheating and on austenitic stainless steel preheated
substrates.

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a, c, e external surface; b, d, f centre of coating; a, b AISI 1020; c, d AISI 304; e, f AISI 410
7 Microstructure of Co based alloy coatings deposited on different substrate materials using a low feed rate and preheating of the substrate steel

exhibiting more irregular beads, and as a consequence,

higher dispersion on the dilution measurements made.
The irregular melt pool geometries, observed in
Fig. 3, together with the low dilution levels measured
on some of the coatings produced, required confirmation of the measured dilution. Therefore EDS analyses
through coating thickness, taking iron as a reference
element, were suggested and done. Dilution trends
assessed by the iron content in the coating are presented
in Fig. 5. The good agreement between dilution levels
evaluated by the two procedures suggests that either of
them can be used, in spite of the low dilution measured
and the irregular melt pool geometries. So in accordance
with the measurements made by the areas ratio procedure,
deposits from set 1 exhibited a higher dilution level

regardless of the substrate steel used. On both sets of

specimens stainless steel substrates exhibited highest
dilutions levels. This can be related to the lower thermal
conductivity of the stainless steels used compared to that
of carbon steel. As heat flows more slowly away from
the melt pool, the solidification rate may be affected,
allowing for better mixing of the melted alloys. Also
during cooling, diffusion mechanisms can operate for
longer periods as higher temperatures are maintained for
longer times in the lower thermal conductivity steels.
From the measurements made using different processing parameters it was clear that with both sets of
specimens, dilution levels had a dependence on substrate
features, with thermal conductivity being the dictating
parameter.

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Co based alloy PTA hardfacing on different substrate steels

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a, c, e external surface; b, d, f centre of coating; a, b AISI 1020; c, d AISI 304; e, f AISI 410
8 Microstructure of Co based alloy deposited on different substrate materials using a high feed rate without preheating
of the substrate steel

Microstructure
Characterisation of the atomised Co based alloy powder
identified the original alloy structure. Further modifications as a consequence of processing procedures and
substrate chemical composition could then be established. Figure 6 reveals the microstructure of the Co
based alloy prior to deposition. As observed by scanning
electronic microscopy, the high carbon Co alloy used in
this work exhibited a hypereutectic structure with
primary hexagonal carbides. These primary carbides
consisted of a phase at the centre surrounded by a
second phase, described as being a tungsten rich phase
surrounded by a chromium rich phase.16,17 A white
dispersed tungsten rich phase was also observed.
Figure 7 shows transverse cross-section microstructures of deposits processed with a low feed rate and
substrate preheating, which resulted in the higher
dilution levels measured. For these high dilution coatings, microstructure can be described as primary
dendrites of cobalt a solid solution between which an

464

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a/carbide eutectic had subsequently formed. It is

interesting to notice that phase distribution varied
within each track from the fusion line to the external
surface. Changes in phase distribution were also
observed to be dependent on the substrate steel.
Figure 8 presents transverse cross-section microstructures as observed near the external surface and at the
centre of the deposits, after processing with a higher
powder feed rate without preheating of the substrate
steel. Under these processing conditions the role of the
substrate chemical composition on the final coating
microstructure was evident. Within this set of coatings
only those deposited on martensitic stainless steel
exhibited a hypoeutectic solidification structure through
the thickness. As for the coatings deposited on carbon
steel and austenitic stainless steel, the a dendrites
characteristic of a hypoeutectic structure was only
evident near the fusion line, changing through the
thickness to an apparent eutectic structure, with
elongated (needle like) shaped carbides. Detailed

Yaedu and DOliveira

Co based alloy PTA hardfacing on different substrate steels

9 Blocky hexagonal carbide observed by SEM in coatings

deposited on AISI 304 with a high feed rate

Published by Maney Publishing (c) IOM Communications Ltd

analysis of these structures revealed the presence of

primary carbides similar to those observed in the as
received atomised powder, with a blocky hexagonal
shape (Fig. 9). They consisted of a discrete light
colour phase at the centre surrounded by a second
phase. Analysis of needle like shaped carbides within a
pore trapped in the coating (Fig. 10), suggested that
the blocky hexagonal carbides might be needles in
cross-section.
Regarding the influence of the chemical composition
of the substrate steel on the coating microstructure,
observations made on the controlled low dilution
deposits made it possible to identify its effects on the
coatings. In fact as mixing of the Co based alloy with
the substrates steels became more significant, its original
hypereutectic microstructure was modified to eutectic
and hypoeutectic and a loss of properties was predicted.

Microhardness and wear performance

11 Microhardness profiles measured on coatings processed with (a) low feed rate and preheating of substrate
steel (X AISI 1020, & AISI 304, m AISI 410); (b) high
feed rate without preheating of the substrate steel
(6 6 AISI 1020, * * AISI 304,
AISI 410)

N N

lower hardness. This behaviour can be associated with

the amount of carbides observed on these coatings. As
dilution levels rose, the influence of processing

Hardness profiles determined on the transverse crosssection of the Co based alloy coatings (Fig. 11)
confirmed predictions made from microstructure and
dilution analyses. The relevance of a controlled dilution
is confirmed by the higher hardness values measured on
coatings processed with a high feed rate without
preheating of the substrate. This set of specimen
hardness values followed dilution levels, with the coatings deposited on carbon steel exhibiting higher hardness and those deposited on martensitic stainless steel

10 Needlelike carbides observed by SEM in coatings

deposited on AISI 304 with a high feed rate

a coatings processed with low feed rate and preheating of

substrate steel; b coatings processed high feeding rate
without preheating of substrate steel
12 Wear rate of PTA Co coatings deposited on different
substrate steels, as a function of applied load

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Co based alloy PTA hardfacing on different substrate steels

parameters seemed to take over the effect of substrate

chemical composition on coating hardness, as all
deposits presented similar hardness.
Regarding wear behaviour, it can be predicted from
the hardness values, following Arched theory,13 that for
the same testing conditions, sliding wear resistance
should increase as surface hardness increases.
Therefore one would expect the effect of the substrate
chemical composition to be more significant on wear
rates measured on coatings with lower dilution levels.
Figure 12 shows the wear rates measured as a function
of the applied load for coatings processed with the two
sets of parameters. On both sets of coatings wear
behaviour differences became apparent for high contact
pressures (higher applied load). As expected, wear rate is
more significant for the high dilution set of coatings.
Confirming previous evaluations, deposits made on
carbon steel resulted in lower wear rates on the two
sets of coatings. As a general trend, for the higher
contact pressures, sliding wear increased as substrate
steel changed from AISI 1020, to AISI 304, to AISI 410.
This reinforces the previous results that claimed that the
chemical composition of the substrate is a determining factor for coating characteristics and subsequent
performance.

Conclusions
For the conditions tested these results lead to some
important conclusions.
1. Plasma transferred arc hardfacing is a satisfactory
technique for use whenever controlled dilution coatings
are required.
2. As a general trend, results showed that lower
dilution deposits were associated with harder coatings
and less severe wear rates.
3. The effects of chemical composition of the
substrate steel overtook the effects of processing
parameters as dilution decreased. When that was the
case, results showed that changing the chemical composition of the substrate steel led to alterations in dilution
levels, microstructure development, coating hardness,
and sliding wear performance.
4. Within the selected substrate steels tested, AISI
1020 carbon steel resulted in lower dilution levels, richer

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carbide microstructure, higher hardness, and lower wear

rates. It was followed by the austenitic stainless steel and
martensitic stainless steel, the latter exhibiting the most
significant wear rate and lower hardness within each set.
Regarding specific applications where high and
reliable performances are a priority, this work has
shown that processing procedures should take into
consideration the effects of the chemical composition
of the substrate material on the final coating features.

Acknowledgements
The authors would like to thank the Universidade
Federal do Parana (UFPR) and Agencia Nacional do
Petroleo (ANP) for funding the present work. Special
thanks are due to Mr Sergio Simoes from Delloro
Stellite for his collaboration during coatings processing,
to Mr Sergio Henke from LACTEC for MEV support,
and to Mr Ada ldo Leite Vieira Junior for conducting
wear tests.

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