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<p>This study comparatively investigates the microstructure, hardness, and abrasive wear behaviour of Fe–Cr–C hardfacing layers deposited on AISI 1020 steel using Shielded Metal Arc Welding (SMAW) and Metal Inert Gas (MIG) welding under varying welding current conditions (130–200 A). The novelty of the work lies in the use of identical Fe–Cr–C consumables and a common substrate for both welding processes, enabling direct process–property comparison under controlled experimental conditions. Microstructural characterization was performed using SEM/EDS and XRD analysis, while Vickers microhardness testing and ASTM G65 abrasive wear testing with statistical validation (ANOVA) were conducted to evaluate mechanical and tribological performance. The results showed that MIG hardfaced specimens developed comparatively finer and more uniformly distributed chromium carbide phases (Cr<sub>7</sub>C<sub>3</sub> and Cr<sub>23</sub>C<sub>6</sub>) with lower dilution and reduced microsegregation than SMAW deposits. MIG specimens also exhibited improved hardness uniformity (570 ± 14 to 615 ± 12 HV) and approximately 16.37% lower abrasive wear loss compared with SMAW specimens. ANOVA results confirmed that both welding process and welding current significantly influenced abrasive wear behaviour (<i>p</i> &lt; 0.05). The findings demonstrate that welding current and deposition process strongly affect carbide formation, hardness distribution, and abrasive wear resistance under single-bead hardfacing conditions.</p>

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Performance Assessment of C–Cr–Fe Hardfacing Coatings Deposited via SMAW and MIG Welding

  • 期刊论文

  • 发表日期：

    2026年7月16日

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  • M. S. Satish,
  • K. M. Kenchi Reddy,
  • C. T. Jayadeva,
  • Mallikarjun Biradar,
  • Harish Hanumanthappa,
  • N. Narendra,
  • Mohan Poojari,
  • S. S. Naveen,
  • Bharath Kumar Shanmugam

摘要

This study comparatively investigates the microstructure, hardness, and abrasive wear behaviour of Fe–Cr–C hardfacing layers deposited on AISI 1020 steel using Shielded Metal Arc Welding (SMAW) and Metal Inert Gas (MIG) welding under varying welding current conditions (130–200 A). The novelty of the work lies in the use of identical Fe–Cr–C consumables and a common substrate for both welding processes, enabling direct process–property comparison under controlled experimental conditions. Microstructural characterization was performed using SEM/EDS and XRD analysis, while Vickers microhardness testing and ASTM G65 abrasive wear testing with statistical validation (ANOVA) were conducted to evaluate mechanical and tribological performance. The results showed that MIG hardfaced specimens developed comparatively finer and more uniformly distributed chromium carbide phases (Cr7C3 and Cr23C6) with lower dilution and reduced microsegregation than SMAW deposits. MIG specimens also exhibited improved hardness uniformity (570 ± 14 to 615 ± 12 HV) and approximately 16.37% lower abrasive wear loss compared with SMAW specimens. ANOVA results confirmed that both welding process and welding current significantly influenced abrasive wear behaviour (p < 0.05). The findings demonstrate that welding current and deposition process strongly affect carbide formation, hardness distribution, and abrasive wear resistance under single-bead hardfacing conditions.