Slurry erosion resistance of boride-based overlays containing boride crystals oriented perpendicularly to the wearing surface

Components exposed to the flow of liquid solutions containing hard particles experience significant material loss. For defined slurry conditions, the extent of damage to the components depends upon their microstructure and the slurry particle impingement angles. This paper presents the research work carried on to develop a gas metal arc welding (GMAW) clad overlay that resists slurry erosion at both low and high particle angles. GMAW overlays containing hard primary Fe2B crystals in a supporting matrix enriched in molybdenum, carbon and silicon have been considered. Cored wires of specific compositions deposited with adapted welding parameters produce weld overlays presenting a peculiar microstructure. These iron boride-based overlays contain fine elongated boride crystals aligned mainly perpendicularly to the wearing surface. This peculiar microstructure is responsible for the outstanding slurry erosion resistance observed at both impinging angles of 30° and 90°. These iron boride-based overlays present a slurry erosion resistance at low and high impinging angles far beyond that observed with known materials including chromium carbide overlays. ► Wear resistant Fe–Mo–B–C–Si overlays. ► Specific deposition parameters lead to peculiar microstructure. ► Fe2B crystals aligned mainly perpendicularly to the wearing surface. ► Carbon and molybdenum toughen the steel supporting matrix. ► Outstanding slurry erosion resistance at impact angles of 30° and 90°.