Performance Analysis of Weld Hardfacings Used in the Sugar/Alcohol Industry

The increasing demand for biofuel has pushed the sugar/alcohol industry to expansion, especially in Brazil. In this industry, the costs linked to equipment wear are significant. Abrasive wear is particularly present, especially in shredder knives, which are produced/repaired by weld hardfacings. In this case, FCAW has become a common choice. Considering the lack of results based on real-work wear conditions in such sector, this study compares the performance of weld hardfacings in laboratory and in industry. Three types of FCAW wires (FeCrC alloys) are assessed and compared to a SMAW electrode. The performance of the hardfacings is determined in terms of wear resistance and related to the microstructures produced. The laboratory test did not replicate the industry conditions. The FeCrC + Nb hardfacings had the best performance in laboratory (similar to the SMAW deposits), but the worst in industry. The FeCrC and FeCrC + Ti hardfacings, respectively, were the worst in laboratory and the best in industry (similar to the SMAW deposits). Spalling was decisive for poor hardfacing performance. The absence of cracks in the FeCrC + Ti hardfacings was crucial for their superior industry performance. A test combining abrasion and impact would better represent the wear really acting on the parts.