USOO5942289A

United States Patent (19) 11 Patent Number: 5,942,289

JackSOn (45) Date of Patent: Aug. 24, 1999
54). HARDFACING ASURFACE UTILIZING A 4,850,524 7/1989 Schick ..................................... 228/102
METHOD AND APPARATUS HAVING A
CHILL BLOCK OTHER PUBLICATIONS
American Welding Society, Welding Handbook, R.L.
75 Inventor: Hewy E. Jackson, Porter, Tex. O'Brien, ed., “Electroslag Welding”, vol. 2, pp. 272-273
73 Assignee: Amorphous Technologies (1991) (No month date).
International, Laguna Niguel, Calif. ASM Handbook, vol. 6, “Electroslag and Electrogas Weld
ing", pp. 274–275 (1993) (No month date).
21 Appl. No.: 08/824,415 Primary Examiner Katherine A. Bareford
22 Filed: Mar. 26, 1997 Attorney, Agent, Or Firm-Gregory Garmong
57 ABSTRACT
(51) Int. Cl. .................................................. B05D 3700
52 U.S. Cl. ..................................... 427/398.2; 427/398.1; A hardfacing apparatus includes a deposition head including
427/446; 427/456; 219/76.11; 219/76.12; a heat Source, a hardfacing material Source, and a chill block
219/76.14; 228/222; 228/46; 118/69; 118/302 having a chill block Surface. The deposition head is posi
58 Field of Search ................................. 427/398.1, 446, tioned at a location So as to deposit a mass of the hardfacing
427/456,398.2; 118/69, 302; 219/76.11, material onto the workpiece surface. The chill block is
76.14, 76.12; 228/222, 46 positioned remote from the deposition head with the chill
block Surface in a facing-but-spaced-apart relation to the
56) References Cited Workpiece Surface, Separated from the workpiece Surface by
U.S. PATENT DOCUMENTS a gap having a dimension between the chill block and the
Workpiece Surface of a Standoff distance Ds. Molten hard
3,558,846 1/1971 Viie ..................................... 219/76.11 facing material is deposited onto the workpiece Surface from
3,696.228 10/1972 Thomas, Jr. et al. ... 219/76.11 the deposition head. Simultaneously, the workpiece Surface
3,742,585 7/1973 Wentzell .............................. 427/398.2 is moved relative to the hardfacing apparatus So that the
4,309,587 1/1982 Nakano et al.. molten hard facing material passes into the gap and is molten
4,321,289 3/1982 Bartsch ................................ 427/398.2 as it enters the gap.
4,373,128 2/1983 Asai et al..
4,570,568 2/1986 Fair ........................................... 118/69
4,707,581 11/1987 Blaskovits et al.. 18 Claims, 3 Drawing Sheets
U.S. Patent Aug. 24, 1999 Sheet 1 of 3 5,942.289

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U.S. Patent Aug. 24, 1999 Sheet 2 of 3 5,942,289
U.S. Patent Aug. 24, 1999 Sheet 3 of 3 5,942.289
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HARDEACING ASURFACE UTILIZING A SUMMARY OF THE INVENTION
METHOD AND APPARATUS HAVING A
CHILL BLOCK The present invention provides a hard facing apparatus
that, when used in the hard facing method of the invention,
BACKGROUND OF THE INVENTION produces an improved hard facing overlay on both flat and
The present invention relates to the hard facing of a curved Surfaces. The hard facing is of nearly constant thick
Surface, and, more particularly, to the deposition of a hard neSS and the hardfacing Surface is Smooth and regular upon
facing deposit having a controlled, uniform maximum thick application, reducing or eliminating the requirements for
neSS and a Smooth Surface. final grinding or machining of the overlay. StreSS relief
Hardfacings of relatively hard materials are positioned cracking of hard facings of many materials is reduced Sub
overlying the Surfaces of relatively Softer Substrate materials Stantially. The hardfacing may be applied to curved Surfaces
in order to protect the Softer materials against Surface more easily and with reduced process control limitations, as
damage Such as erosion, galling, and corrosion. The hard compared with the conventional techniques. The hardfacing
facing material may be provided in any of Several ways. In deposition rate is increased significantly, improving the
one approach, the hard facing material is melted, contacted to 15
process economics. The heat loading into the workpiece is
the Substrate, and allowed to Solidify against the Substrate. relatively small.
This technique is Sometimes termed welding because the In accordance with the invention, a method of hard facing
hard facing deposit is joined to the Substrate by Solidification, a workpiece comprises providing a workpiece having a
but is distinct from the other type of welding wherein two Workpiece Surface, and providing a hard facing apparatus
Solid pieces are joined together by a molten weldment. comprising a deposition head and a chill block having a chill
In hard facing by welding, the Substrate is moved relative block surface. The chill block is preferably made of a
to the heat Source and hard facing material Source. The high-thermal-conductivity material that is water cooled. The
hard facing material initially forms a molten pool on the deposition head includes a heat Source and a hardfacing
Substrate Surface, which thereafter Solidifies as the heat material source. The chill block is positioned remote from
Source moves away from an area and heat is removed from 25 the deposition head with the chill block Surface in a facing
the molten pool. The heat input from the heat Source is but-Spaced- apart relation to the workpiece Surface. The chill
usually adjusted So that the underlying Substrate is melted to block is separated from the workpiece Surface by a gap
a shallow depth at its Surface. Consequently, the molten having a dimension between the chill block and the work
hard facing material and the melted region at the Surface of piece Surface of a standoff distance Ds. Molten hard facing
the substrate material locally mix, with the result that, after material is deposited onto the workpiece Surface from the
Solidification of the hard facing, there is a good interfacial deposition head at a location remote from the gap. The
bond between the hard facing deposit and the Substrate. Workpiece Surface is moved relative to the hard facing appa
While operable and widely used in industry, hardfacing by ratus. Such relative movement is achieved either by moving
welding has drawbacks in Some applications. Due to Surface the Substrate, or the heat Source and hard facing material
tension and other effects, upon Solidification the hardfacing 35 Source, or both. AS the hardfacing material is deposited, the
deposit is relatively irregular with a bumpy Surface. For molten hardfacing material passes into the gap Such that a
applications requiring a Smooth Surface, the hard facing free Surface of the molten hard facing material deposited
overlay must thereafter be ground or machined to make the onto the workpiece Surface remains molten as it enters the
Surface Smoother, an expensive and time-consuming opera gap.
tion. After grinding or machining, there may still be irregu 40 In a particularly advantageous application, the workpiece
larities in the Surface of the hardfacing overlay, between low has a locally curved Surface of constant conveX radius of
spots and the machined or ground region. Surface cracks due curvature R. The chill block Surface has a constant concave
to StreSS relief are Sometimes found in the hardfacing, which radius of curvature of R+Ds. AS the molten material of the
can lead to penetration of erosive or corrosive agents into molten pool passes into the gap between the workpiece and
and through the hard facing overlay. Such StreSS relief cracks 45 the chill block Surface, the chill block Surface evens out the
are acceptable in limited numbers and particular orienta molten pool by causing a lateral flow of the molten material
tions. However, it is preferred to reduce the incidence of to fill in adjacent Shallow regions with exceSS material from
cracking. other regions. The chill block Surface also Smooths the upper
Additionally, it is difficult to apply a regular and uniform Surface of the molten material and accelerates its cooling
hard facing deposit circumferentially onto a curved Surface, 50 and Solidification to produce a Smooth, regular Surface on
Such as the Surface of a cylindrical pipe or shaft. The curved the final hard facing weldment. The presence of the chill
Surface must be held horizontal, and the molten pool must be block also reduces the requirement for tight process control
applied very near the top dead center of the horizontal on the precise positioning of the deposition head. The
region. Even then, because the Solidification requires a molten pool is permitted to run down the curved Surface,
period of time, the surface must be moved relatively slowly 55 because the chill block Surface limits the extent of the
so that the still-molten pool does not run down the curved running of the moltenhardfacing material and, in any event,
Surface, resulting in wide variations in the thickness of the Smooths and evens the molten material that does run.
deposit. This slow movement reduces the production rate, In one application of this type of interest to the inventor,
with adverse effects on the economics of the hard facing a hardfacing band is applied around the circumference of a
processing. And, even when the movement of the Surface is 60 cylindrical pipe. The pipe is rotated about its cylindrical axis
relatively slow, the molten pool is often deformed and under a Stationary deposition head and chill block. Because
irregular, further increasing the tendency to Surface irregu of the presence of the chill block, there is much less concern
larity of the final solidified deposit. with running of the molten material and the need for precise
There is a need for an improved approach to hardfacing by positioning of the deposition head. The use of the hard facing
welding that overcomes these drawbacks. The present 65 approach of the invention results in an increased deposition
invention fulfills this need, and further provides related rate nearly double that achieved by the conventional
advantages. method.
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In addition to improving the proceSS economics, the facing band uniformly around the circumference of the pipe,
approach of the invention also results in a Substantially and the hard facing band, once deposited, requires extensive
improved hardfacing layer and improved metallurgical grinding to Smooth its Surface prior to use. There is a
Structure in the hardfacing layer. The gap between the chill Substantial amount of StreSS relief cracking of the bands
block and the workpiece Surface results in a hard facing layer deposited by the prior approach.
of nearly constant thickness. The contact of the chill block A hardfacing apparatuS 46 according to the present inven
Surface to the molten pool Smooths the molten hardfacing tion is provided, numeral 22. The hard facing apparatus 46
material and results in greatly reduced Surface irregularities includes two major components, a deposition head 48 and a
in the solidified hard facing weldment. In trials conducted by chill block 50. The deposition head 48 heats and deposits the
the inventor, the hardfacing bands produced on cylindrical molten hardfacing material onto the Surface 42 at a location
pipes were So Smooth and regular that no Subsequent remote from the chill block 50. Any operable deposition
machining or grinding was required. The metallurgical device may be used. In the preferred approach, the deposi
Structure of the hardfacing is improved, with greatly reduced tion head 48 uses a hard facing material source 52 in the form
incidence of StreSS relief Surface cracking many materials of a wire having the composition of the hard facing material.
that may be applied by this approach. 15 A heat Source 54 includes an annular electrode 56 and a
The deposition head is laterally separated from the chill power Supply 58 that applies a Voltage between the work
block during the deposition operation. The heat Source of the piece (pipe 40) and the electrode 56. The hardfacing material
deposition head may therefore be Selected as appropriate to Source 52 is fed through the center of the electrode 56, where
it contacts the electrode 56. The electrical current that flows
the particular hard facing application. The deposition head through the circuit including the power Supply 58, the pipe
and the chill block may be optimized and moved indepen 40, the hard facing material source 52, and the electrode 56
dently of each other. heats the end of the hardfacing material Source 52 as it
Other features and advantages of the present invention contacts the Surface 42. The hard facing material Source 52 is
will be apparent from the following more detailed descrip melted to form a molten pool 60 of the hard facing material
tion of the preferred embodiment, taken in conjunction with 25 on the Surface 42 of the pipe 40. The near-surface region of
the accompanying drawings, which illustrate, by way of the pipe 40 under the molten pool is also typically melted to
example, the principles of the invention. The Scope of the a shallow depth. The hard facing material mixes with the
invention is not, however, limited to this preferred embodi melted base metal of the pipe, resulting in a strong bond of
ment.
the hard facing material to the pipe upon later Solidification.
BRIEF DESCRIPTION OF THE DRAWINGS The deposition head 48 may be of any operable type. The
illustrated electrical heating approach is preferred, but the
FIG. 1 is a block diagram of a method according to the heat Source could be a laser, a plasma Source, or any other
invention; operable heat Source. Because the deposition head 48 is
FIG. 2 is a Sectional view of a cylindrical workpiece and remote from the chill block 50, the design of each is not
hard facing apparatus; 35 constrained by the design of the other and the requirement
FIG. 3 is an elevational view of the workpiece and that they fit together in close proximity. The deposition head
hard facing apparatus of FIG. 2; 48 may be precisely controlled, and may be moved closer to
FIG. 4 is a schematic enlarged detail of FIG. 2; or further from the chill block 50 as required for particular
Workpieces and hardfacing materials.
FIG. 5 is a Schematic detail of an apparatus using a 40 The hardfacing material may be any operable material. A
cylindrical chill block; and preferred Such hardfacing material, available from Amor
FIG. 6 is a Schematic detail of an apparatus using a flat phous Technologies International, Laguna Niguel, Calif., as
chill block. Armacor M*TM alloy, has a composition in weight percent of
DETAILED DESCRIPTION OF THE about 27.75 percent chromium, about 6.0 percent nickel,
INVENTION 45 about 3.45 percent boron, about 1.8 percent manganese,
about 1.05 percent Silicon, 0.2 percent maximum carbon,
FIG. 1 is a block diagram of a preferred method for balance iron. Other operable hardfacing materials include
practicing the invention, and FIGS. 2-4 are views of the alloys containing phases Such as tungsten carbide and chro
hard facing apparatus and workpiece. A workpiece is mium carbide, austenitic alloys Such as manganese Steels,
provided, numeral 20. The workpiece of FIGS. 2-4 is a 50 and high-alloy Steels used for corrosion resistance, erosion
hollow cylindrical pipe 40 having an exterior workpiece resistance, Strength and corrosion resistance, and/or Strength
Surface 42, the preferred application at this time. A hardfac and erosion resistance. The workpiece may be any operable
ing layer is to be applied to the Surface 42 in the form of material, but Steel is preferred.
circumferentially extending bands 44 that are typically 1 The hard facing apparatus 46 further includes the chill
inch wide and /8 inch thick. The Surface 42 has a radius of 55 block 50. The chill block 50 is a body having a chill block
curvature R. The present invention is equally applicable to surface 64 curved to conform to the shape of the surface 42
the hard facing of other forms of Surfaces 42, Such as of the pipe 40, allowing for a separation from the Surface 42
irregularly curved Surfaces and flat Surfaces. by a preselected distance. In the illustrated case, the chill
The presently preferred application is of particular interest block Surface 64 is a conveX Segment of a cylinder. In
because hard facing bands have, in the past, been applied to 60 operation, the chill block 50 is positioned in a facing-but
downhole pipe used in the oil-drilling industry. The bands Spaced-apart relationship to the pipe 40, with a gap 66
contact against an inside Surface of an overlying pipe casing therebetween. The gap 66 has a dimension Ds that defines a
(not shown) as the pipe 40 is rotated to turn a bit at the end standoff distance of the chill block 50 from the pipe 40. The
of the pipe in the drilling operation. The Surface of the chill block surface 64 therefore has a cylindrical radius of
hard facing band must be Smooth, as it rides against the 65 curvature R+Ds. In the event that the workpiece is flat or
inside Surface of the pipe casing. In conventional hardfacing of Some other curved configuration, the chill block Surface
approaches, it is quite difficult and Slow to deposit a hard is shaped accordingly.
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The chill block 50 is water cooled. In the illustrated arrow 84, numeral 30. Molten material in the pool 60 is
embodiment, the chill block 50 is formed of sheet or plate carried into the region of the gap 66 between the chill block
material So that an entire interior 68 of the chill block 50 is Surface 64 and the Surface 42.
hollow. Water is flowed through the interior 68 of the chill FIG. 4 illustrates the result. The molten pool naturally has
block 50 via an inlet pipe 70 and an outlet pipe 72. Other irregularities in the amount of hardfacing material present at
operable configurations may also be used. For example, the any location along the direction parallel to the cylindrical
chill block may be a block with cooling channels running axis 82. These variations are in part responsible for the
therethrough. The chill block could also be a solid body with uneven Surface of hard facings made by the prior approaches.
cooling provided by a spray against its opposite Surface In the present approach, any exceSS material 86 in a local
remote from the workpiece. region of the molten pool 60 is prevented from entering the
The chill block 50 is preferably formed of a material gap 66 by a leading edge 88 of the chill block 50. Such
having a high thermal conductivity, most preferably at least excess material 86 flows in the direction parallel to the
about 90 BTU/ft-hr-°F., for hardfacing with the preferred cylindrical axis 82 (i.e., into or out of the plane of the page
hard facing materials. The material of construction is desir in the view of FIGS. 2 and 4, and parallel to the horizontal
ably copper (including unalloyed copper and copper alloys) 15 in the view of FIG. 3). This evens out the irregularities that
or aluminum (including unalloyed aluminum and aluminum would otherwise be present, resulting in a much more
alloys), both of which have relatively high thermal conduc uniform thickness of the final solidified hard facing layer 90.
tivity and Sufficient mechanical Strength. Copper alloys and Additionally, an outwardly facing free surface 87 of the
aluminum alloys are most preferred, So as to avoid excessive hardfacing material of the molten pool 60 Solidifies against
wear of the chill block 50. In some instances, however, it the chill block surface 64, which is made relatively smooth.
may be desirable to cool the moltenhardfacing deposit more The interface between the liquid and the Solid hard facing
Slowly, and a non-cooled chill block, or a chill block made material in the molten pool 60 is indicated schematically by
of material of lower thermal conductivity, may be used. In a liquid-solid interface 92. Solidification of the molten pool
yet other cases, the chill block could be heated to remove 60 starts at a location 93 near to the deposition head 48, and
heat from the hardfacing material more Slowly. In all Such 25 against the workpiece (the pipe 40). The free (outwardly
instances, the “chill block' terminology remains facing) Surface of the molten pool 60 remains liquid,
because heat transfer from the free Surface to air is much
appropriate, because the molten hard facing material is
chilled by its contact with the block. slower than heat transfer from the hardfacing material into
the workpiece. The liquid-solid interface 92 is therefore
The deposition head 48 and the chill block 50 may be angled outwardly with increasing distance from the deposi
independently Supported, or, more preferably, are Supported tion head 48. Significantly, the molten hard facing material at
together in a carriage 74. The carriage 74 Supports the and near the free surface 87 of the molten pool 60 remains
deposition head 48 and the chill block 50 in a desired fixed liquid as it reaches the leading edge 88, So that the last of the
relation to each other and to the workpiece. In the case of the molten pool 60 to solidify does so in contact with the
workpiece in the form of the pipe 40, the carriage 74 35 cooling/shaping Surface 64 within the gap 66. The result of
includes wheels 76 (or equivalently, Stationary spacers) that the hard facing material Solidifying in this manner is a Strong
rest against the surface 42 of the pipe 40 and springs 78, bond of the hard facing layer 90 to the workpiece, and also
reacting with the frame of the carriage, that hold the depo a smooth free surface 94 of the hard facing layer 90. There
Sition head and chill block in a desired relation to each other is little oxidation of the free Surface 94 because it is molten
and to the Surface 42.
40 for only a short time-the time necessary for the Surface of
The deposition head 48 is positioned relative to the pipe the workpiece to move the distance between the deposition
40, numeral 24. The deposition head 48 is preferably posi head 48 and the cooling/shaping head 50. Tests conducted
tioned at a circumferential location near the top-dead-center by the inventor on the hardface banding of pipes, as shown
position 80 of the pipe 48, but need not be at exactly the top. in FIGS. 2-3, demonstrated that the outer Surface 94 of the
The deposition head 48 is spaced a distance from the pipe 45 hard facing layer is Sufficiently Smooth that no post
Suitable for the particular type of deposition head Selected. hardfacing machining or grinding is necessary, an important
The chill block 50 is positioned radially adjacent to the and major cost Savings in the production operation.
pipe 40 and circumferentially relative to, but remote from, The presence of the chill block and the controlled solidi
the deposition head 48, numeral 26. The chill block 50 is fication of the molten pool in the gap 66 results in an ability
positioned radially relative to the pipe 40 with the chill block 50 to conduct the hardfacing operation much faster than in prior
surface 50 the standoff distance Ds from the surface 42. The approaches. In the prior approaches, it was necessary to
chill block 50 is positioned circumferentially a distance from position the deposition head at a location very close to
the deposition head 48 such that, when the pipe 40 is rotated top-dead-center of the pipe and to rotate the pipe relatively
about its cylindrical axis 82 in the direction indicated by the slowly so that the molten pool would solidify before the pipe
arrow 84, at least some of the molten pool 60 will extend to 55 had rotated to a degree that molten hard facing material
the chill block 50. Stated alternatively, at least some of the would run down the face of the pipe. The containment effect
hard facing material in the molten pool 60, at and near its free achieved by the chill block 50, as illustrated at numeral 86
Surface, will be molten as it enters the gap 66 between the in FIG. 4, allows the pipe to be rotated much faster, also
pipe 40 and the chill block surface 64. The circumferential reducing the cost of the hard facing operation. In the prior
angular separation between the deposition head 48 and the 60 processing approach, the hard facing of a 6-5/8 inch outside
chill block 50 is typically from about 10 to about 60 degrees. diameter pipe required a time of about 130-160 seconds per
The configuration of the carriage is Selected to maintain hardfacing band. In the present approach, that time is
these positional relationships. reduced to about 80 Seconds per hard facing band, with
The deposition head 48 is operated to feed hard facing improved Surface and microstructure of the hard facing band.
material, melt the hardfacing material, and form the molten 65 Metallurgical Studies have demonstrated that the metal
pool 60, numeral 28. Simultaneously, the pipe 40 is rotated lurgical Structure of the hardfacing material produced by the
about its cylindrical axis 82 in the direction indicated by the present approach is Superior to that of the hard facing mate
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rial produced by the prior approach, for at least Some the workpiece Surface, the chill block being Separated
materials. In the case of the most-preferred Armacor M* from the workpiece Surface by a gap having a dimen
hard facing material, the number of StreSS relief cracks in the sion between the chill block and the workpiece surface
hard facing material is reduced to leSS than about 4 the of a Standoff distance Ds;
number found in the hard facing bands produced by the positioning the deposition head to deposit a mass of the
present approach as compared with hardfacing bands pro hardfacing material onto the workpiece Surface at a
duced by the prior approach. In many cases, there were no location remote from the gap,
StreSS relief cracks in the Armacor hard facing produced by depositing molten hardfacing material onto the workpiece
the present approach. Surface from the deposition head Such that there is a
The chill block may have other operable configurations free Surface to air of a molten hard facing material
than the one illustrated. The chill block 50 may be a hollow between the deposition head and the chill block; and
roller, ball, or other configuration, as shown in FIG. 5. The moving the workpiece Surface relative to the hard facing
cylindrical chill block 50 is mounted on bearings and turns apparatus, the chill block being positioned at a location
with the movement of the workpiece. Such chill blocks have Such that the moltenhard facing material passes into the
the advantages that they roll rather than Slide, reducing 15 gap and Such that a free Surface of the molten hardfac
ing material deposited onto the workpiece Surface
Surface wear, and can be made to trace over the Surfaces of remains molten as it enters the gap.
irregularly curved workpieces. They have the disadvantage 2. The method of claim 1, wherein the step of providing
that the cooling power is lower, because less of their Surface a workpiece includes the Step of
contacts the hardfacing layer. The chill block may also be providing a workpiece having a locally curved Surface of
flat, as shown in FIG. 6, for use with a flat workpiece. constant radius of curvature R, and
The present approach is distinct from hardfacing by the wherein the Step of providing a hard facing apparatus
electroslag melting approach, which has been previously includes the Step of
used to apply continuous hard facings (as distinct from providing a chill block Surface having a radius of
bands) to cylindrical workpieces Such as rolling mill rolls. In 25
curvature equal to R+Ds.
that technique, a water-cooled shoe is placed adjacent to the 3. The method of claim 1, wherein the step of providing
Surface of the workpiece. Hardfacing metal is melted into a workpiece includes the Step of
the Space between the water-cooled shoe and the workpiece providing a workpiece having a locally Substantially
by a consumable electrode arc. A slag is maintained on the cylindrical workpiece Surface, and
Surface of the molten metal to protect it against oxidation wherein the Step of providing a hard facing apparatus
during the prolonged molten period, usually limiting the includes the Step of
Workpiece to a vertical orientation. The melting requires a providing a chill block Surface having a curvature
very large power input, which melts not only the hard facing selected to conform to that of the substantially cylin
material but a substantial depth of the substrate. The Sub drical workpiece surface with the standoff distance
Strate is significantly heated and the hard facing material is 35
Ds.
diluted by the excess melted Substrate material. In the 4. The method of claim 3, wherein the step of moving the
present approach, because the deposition Source is remote Workpiece Surface relative to the hard facing apparatus
from the gap between the chill block and the workpiece, the includes the Step of
heat flow into the cooling/shaping head is much Smaller and, maintaining the hard facing apparatus in a fixed location,
consequently, the power required from the heat Source is 40
and
much less. There is leSS heating and melting of the under rotating the workpiece about a cylindrical axis of the
lying workpiece Substrate, and less dilution of the hardfac Substantially cylindrical workpiece Surface.
ing material. There is, accordingly, greater latitude in the 5. The method of claim 1, wherein the step of providing
Selection of the hard facing material and of the heat Source. a hardfacing apparatus includes the Step of
In the present approach, the Surface being hardfaced is open 45 providing a water-cooled chill block.
to View, So that inspection is easier and automated control 6. The method of claim 1, wherein the step of depositing
techniques may be readily used. The approach of the present molten hard facing material includes the Step of
invention may be utilized with non-vertical orientations of depositing an excess of the molten hardfacing material
the workpiece, and with workpieces Such as hollow pipes above that required to provide the thickness of the final
that would be difficult or impossible to hardface because of 50 hardfacing deposit.
the high heat input inherent in electroslag hard facing. 7. The method of claim 1, wherein the step of providing
Although a particular embodiment of the invention has a hardfacing material Source includes the Step of
been described in detail for purposes of illustration, various providing a Source of a material Selected from the group
modifications and enhancements may be made without consisting of an alloy having a composition in weight
departing from the Spirit and Scope of the invention. 55 percent of about 27.75 percent chromium, about 6.0
Accordingly, the invention is not to be limited except as by percent nickel, about 3.45 percent boron, about 1.8
the appended claims. percent manganese, about 1.05 percent Silicon, 0.2
What is claimed is:
1. A method of hard facing a workpiece, comprising: percent maximum carbon, balance iron; an austenitic
Steel; an alloy containing a tungsten carbide phase; and
providing a workpiece having a workpiece Surface; 60 an alloy containing a chromium carbide phase.
providing a hard facing apparatus, comprising: 8. The method of claim 1, wherein the step of providing
a deposition head including a hardfacing apparatus includes the Step of
a heat Source, and providing a deposition head further including
a hard facing material Source, and a carriage, and
a chill block having a chill block surface; 65 a carriage Support that positions the hardfacing material
positioning the chill block at a location with the chill Source at a preselected deposition distance from the
block Surface in a facing-but-spaced-apart relation to Workpiece Surface; and
 5,942,289
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affixing the heat Source and the hardfacing material Source percent of about 27.75 percent chromium, about 6.0
to the carriage. percent nickel, about 3.45 percent boron, about 1.8
9. The method of claim 1, wherein the step of providing percent manganese, about 1.05 percent Silicon, 0.2
a hard facing apparatus includes the Step of percent maximum carbon, balance iron; an austenitic
providing the chill block having the chill block surface Steel; an alloy containing a tungsten carbide phase; and
made of a material having a thermal conductivity of at an alloy containing a chromium carbide phase.
least about 90 BTU/ft-hr- F. 13. The method of claim 11, wherein the step of providing
10. The method of claim 1, wherein the step of providing a hardfacing apparatus includes the Step of
a hard facing apparatus includes the Step of providing a deposition head further including
providing the chill block having the chill block surface a carriage, and
made of a material Selected from the group consisting a carriage Support that positions the hardfacing material
of copper and aluminum. Source at a preselected deposition distance from the
11. A method of hard facing a workpiece with a hard facing Workpiece Surface; and
deposit of thickneSSDs, comprising:
providing a Substantially cylindrical workpiece having a 15 affixing the heat Source and the hard facing material Source
Substantially cylindrical workpiece Surface of constant to the carriage.
conveX radius of curvature R, 14. The method of claim 11, wherein the step of providing
providing a hard facing apparatus, comprising: a hardfacing apparatus includes the Step of
a deposition head including providing the chill block having the chill block surface
a heat Source, and made of a material having a thermal conductivity of at
a hard facing material Source, and least about 90 BTU/ft-hr- F.
a chill block having a chill block surface with a 15. The method of claim 11, wherein the step of providing
constant concave radius of curvature equal to a hardfacing apparatus includes the Step of
R+Ds; 25 providing the chill block having the chill block surface
positioning the deposition head at a location So as to made of a material Selected from the group consisting
deposit a mass of the hardfacing material onto the of copper and aluminum.
Workpiece Surface; 16. A hard facing apparatus used to apply a hardfacing to
positioning the chill block remote from the deposition a Surface of a workpiece, comprising:
head with the chill block surface in a facing-but a water-cooled chill block having a chill block Surface, the
Spaced-apart relation to the workpiece Surface, the chill chill block Surface being in a facing-but-spaced-apart
block being Separated from the workpiece Surface by a relation to the Surface of the workpiece with a gap
gap having a dimension between the chill block and the between the chill block surface and the workpiece
Workpiece Surface of Ds; Surface;
35
depositing molten hardfacing material onto the workpiece a hard facing material Source; and
Surface from the deposition head Such that there is a a heat Source operable to heat and melt the hard facing
free Surface to air of molten hard facing material material Source, and to deposit the melted hard facing
between the deposition head and the chill block; and material Source onto the Surface of the workpiece at a
rotating the workpiece about its cylindrical axis relative to 40 location remote from the gap Such that there is a free
the hardfacing apparatus, the chill block being posi Surface to air of a molten hardfacing material between
tioned at a location Such that the molten hard facing the hardfacing material Source and the chill block.
material passes into the gap and Such that a free Surface 17. The apparatus of claim 16, wherein the workpiece
of the molten hardfacing material deposited onto the Surface is Substantially cylindrical.
Workpiece Surface remains molten as it enters the gap. 45 18. The apparatus of claim 16, wherein the chill block
12. The method of claim 11, wherein the step of providing Surface is made of a material Selected from the group
a hard facing material Source includes the Step of consisting of copper and aluminum.
providing a Source of a material Selected from the group
consisting of an alloy having a composition in weight k k k k k