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EROSION RESISTANCE OF INFILTRATION BRAZED TUNGSTEN CARBIDE

CLADDING

Authors:
Chad Juliot
D. W. Bucholz, Ph.D.

Conforma Clad
501 Park East Blvd.
New Albany, IN 47150

ABSTRACT

Infiltration brazed tungsten carbide wear protection, as an alternative to weld overlay, has been shown to be superior
in pulp and paper mill applications, where severe erosion, corrosion and abrasion are the primary mechanisms of
failure. A material’s erosion resistance is determined by several factors, including the size and spacing of the
material’s hard particles and the method of application. Other important variables include the characteristics, impact
angle, and velocity of the eroding media.

This paper discusses the advanced erosion, abrasion, and corrosion-resistant characteristics of three infiltration
brazed tungsten carbide claddings as compared to common wear protection materials using standardized laboratory
testing methods. This paper will also review field results from various infiltration brazed tungsten carbide cladding
applications, including a pump installed at the underflow of a white liquor clarifier, a power boiler induced draft fan,
and a conveyance system transporting glass-filled plastic compounds.

INTRODUCTION

The erosion of steel equipment can create costly equipment replacements, unscheduled downtime, and reductions in
mill productivity. The use of wear protection on components, such as induced draft fans, chutes, screws, elbows,
pumps, and other material conveyance components, can enable mills to reliably extend scheduled outage cycles
while reducing maintenance budgets and diminishing the risk of unexpected downtime. The latest results of
standardized testing and field experiences, as presented in this paper, demonstrate that infiltration brazed tungsten
carbide claddings offer improved equipment protection when compared to other common wear-resistant coatings in
highly erosive, abrasive, and corrosive environments.

STANDARDIZED EROSION RESISTANCE TESTING

This paper will review the basics of infiltration brazed tungsten carbide claddings, test conditions and results from
standardized laboratory testing. The erosion resistance of common wear protection materials has been examined at
varying impact angles and particle velocities to better approximate actual conditions within a mill environment

When evaluating the erosion resistance of materials, a number of factors must be considered. Obvious factors
include temperature, velocity of the impacting particles, their size and shape and the impacting angle. These factors
can be controlled in standardized testing, but combining their range of variability to comprehensively evaluate
performance is limited.

Standardized testing procedures, including ASTM G76 (1) reduce a number of variables with the intent of providing
a common baseline for comparison. The issue with such standardized tests is that the differences in erosion rates
can be diminished to the point where differentiation is difficult or misleading. Short of full-scale tests, this leaves
variation of the standardized tests as the only means to more accurately mimic actual conditions and rank erosion
resistance in a meaningful way.

ASTM G76 laboratory testing was performed on common wear protective materials to determine their level of
erosion resistance. Materials tested included 1018 low carbon steel, chrome carbide weld overlay, 400 Brinnell
heat-treated hard-plate, solid tungsten carbide and three variations of infiltration brazed tungsten carbide claddings.

Infiltration Brazed Tungsten Carbide Cladding

Infiltration brazing, as defined in this paper, involves filling by capillary action with molten filler metal, a porous
coating or structure that has a melting point higher than the filler metal. In this case, the molten filler metal is a
combination of nickel, chrome and boron (NiCrB) and the porous structure is tungsten carbide. The tungsten
carbide and NiCrB powders are formed into separate non-woven, preformed cloths that are temporarily adhered to
the desired substrate. The substrate is then placed in a vacuum furnace and, at temperatures in excess of the melting
point, the NiCrB brazes to the substrate forming a matrix of NiCrB and the tungsten carbide particles.

Multiple cladding formulations can be engineered to protect applications in various wear environments. Standard
infiltration brazed tungsten carbide cladding formulas include Conforma Clad®’s WC200, WC210 and WC 219.
Custom claddings can also be engineered for unique wear applications.

A photomicrograph of infiltration brazed tungsten carbide cladding

is shown in Figure 1. The tungsten carbide particles are the sizable
gray chunks in the top portion of the photomicrograph and the
NiCrB filler metal is contained between the tungsten carbide Tungsten Carbide
particles and at the interface between the substrate and the cladding.
It is also important to note that the claddings increased erosion
performance is related to the amount of mean free space between the
tungsten carbide particles, with lower amounts of free space yielding
greater erosion resistance.
NiCrB
The constraints on this process are straight-forward. The infiltration
brazing process is performed in a vacuum furnace. Large parts as
measured by volume, weight or area, are often segmented prior to Substrate
cladding to avoid the limitations of furnace size. Another barrier
arises when parts that tend to distort during the brazing process
Figure 1. Photomicrograph of Infiltration Brazed
cannot be straightened or machined back to their original Tungsten Carbide Cladding
specifications. Also, substrates such as aluminum and low melting
alloys cannot currently be protected by this process.

Test Procedures

The ASTM G76 test method standardizes the determination of a materials erosion rate by solid particle impingement
in a gas stream. Actual erosion conditions involve particle sizes, velocities, angles of attack, as well as various
operating environments. Consequently, a single test is usually insufficient for evaluating expected performance over
all conditions.

Test materials include:

• 1018 Low Carbon Steel
• Chrome Carbide Weld Overlay
• AR400 – 400 Virnell Heat-Treated Hard Plate
• Solid Tungsten Carbide
• Infiltration Brazed Tungsten Carbide Claddings
Figure 2, represents the test apparatus used to determine the erosion rates discussed in this paper. The nozzle’s
inside diameter was 6.4 mm (0.25″) by 152 mm (6″) long. The length-to-diameter ratio was 24:1, minimum
recommended in the ASTM G76 procedure is 25:1.
Variable Feed
Low Pressure Control
Regulator Mass Flow
Particle (orifice plate)
High Pressure Feed
Regulator
Erosion
Chamber

Sample
High
Pressure Dryer
Air In

Mixing Acceleration
Chamber Tube

Dust
Collector
Water
Manometer

Figure 2. Schematic of ASTM G76 Erosion Test Apparatus

First, calibration of particle velocity was performed. The ASTM procedure provides test data at 30 and 70 m•s-1
(98-230 ft•s-1) for 1020 steel at a 90° impact angle for interlaboratory tests. The standard deviation and deviation
between laboratories (provisional) are also given in the standard. The standard recommends the use of a rotating
double-disk, laser velocimeter or high-speed photography as methods to measure particle velocity at the sample.
This work relied exclusively on velocity calibration by duplication of the standard data given in the ASTM G76
procedure. The material used for calibration was 1018 steel, annealed, 71 HRB.

Test Results and Discussion

The differences in erosion behavior are generally categorized by broad descriptions of the type of wear. In general,
soft materials erode by plowing or cutting when impacted at low angles. Relatively soft materials can be
distinguished from relatively hard, erosion-resistant materials by the fact that their erosion rates tend to increase at
lower angles of impact. Erosion rates are also influenced by the amount of spacing between the material’s hard
particles. It has been shown that as the distance between a material’s hard particles decreases, so does the material’s
erosion rate.
 Erosion Resistance and Impact Angle

Figure 3 illustrates the erosion rates of various

materials as a function of the impact angle of the
eroding media on the material. This figure
demonstrates the negative correlation aspect of
the erosion rate is exemplified by the behavior of
1018 steel over the 30° to 90° impact angle
range. There is also a negative correlation for
the weld overlay and the AR400 material at
impact angles greater than 60°. Below the 60°
impact angle, the weld overlay, AR400 and
infiltration brazed tungsten carbide claddings
show a positive correlation, although the slope of
the latter decreases with increasing impact
angles.
Figure 3. Erosion Rate vs. Impact Angle
Erosion rate of various materials measured at 230 ft•s (70 m•s-1) using 50
-1
The particle erosion of alloys and composite
µm alumina, 2.1 g/min., tube diameter 0.25 in. (6.4 mm).
coatings is strongly influenced by the
impingement angle of the eroding particles. The
ASTM G76 standard provides a reasonable correlation of laboratory data to field performance. The magnitude of
volume loss per unit mass of eroding media delivered allows for a relative ranking of erosion rates.

Relatively softer materials will erode at a greater rate at a decreasing angle, while the converse is true for relatively
harder materials. At an impact angle of 90°, the materials tested showed less of a relative difference than at other
angles of impingement.

Erosion Resistance and Hard Particle Distribution

Alternatively, tungsten carbide cermets show improved erosion

resistance in a manner related to the binder content. Uuemyis
and Kleis (2) verified a mechanism which eroded the metallic
binder from around carbide grains. By maximizing the area of
carbide presented to the eroding media (minimizing binder
content), erosion resistance could be increased by a factor of
three or four at a minimum, and as much as ten to fifteen times
at a maximum, compared to cermets with high binder content
(>40 volume percent) or metallic alloys, respectively.

This establishes that the erosion performance of a composite

material is related to the mean free space between particles.
Mean free space is defined as the distance between a material’s
hard particles. Figure 4 demonstrates the relationship between
the erosion rate and the mean free path of infiltration brazed
tungsten carbide cladding at 45° and 90° angles of impact, as Figure 4. Erosion rate of infiltration brazed tungsten
found in ASTM G76 standardized testing. This figure shows carbide as a function of mean free path.
that as the mean free path decreases, so does the erosion rate. Test conditions: 70 m/s using 50 µm alumina, 2.1 g/min.,
tube diameter 6.4 mm (0.25 in.)
Based on ASTM G76 testing and results from field testing,
infiltration brazed tungsten carbide claddings eroded at a rate of
1/15th to 1/4th that of chrome carbide weld overlay in the 30° to 90° range of impingement angles, respectively. The
erosion rate of infiltration brazed tungsten carbide composites is a function of the carbide spacing (mean free path).
This dependence has also been characterized on the basis of matrix material. The greater the percentage of matrix
contained within the composite, the lower the erosion resistance.
Standardized ASTM G76 testing demonstrates the elevated erosion resistance of infiltration brazed tungsten carbide
cladding within a controlled laboratory setting. Similar results have also been established in standardized abrasion
and corrosion testing.

STANDARDIZED ABRASION AND CORROSION RESISTANCE TESTING

Standardized testing following ASTM procedures were also conducted to determine the abrasion and erosion
resistance of various wear protective materials. Infiltration brazed tungsten carbide cladding outperformed other
substrate materials in both of these tests.

Abrasion Resistance Factor

The abrasion resistance of three infiltration brazed tungsten carbide claddings was compared to low carbon steel
(1018), heat-treated 400 Virnell hard plate (AR 400), chrome carbide weld overlay and solid tungsten carbide. The
abrasion resistance was evaluated using the ASTM G65-94, Procedure A test method, with 6,000 revolutions, 200
RPMs and a 30 pound load.

The resulting abrasion resistance factor (ARF) is the inverse of the volume loss (mm3) during the test procedure.
Higher ARF materials have a greater resistance to abrasion than those with lower ARF values. Figure 5 illustrates
the AFRs of the several materials. All three infiltration brazed tungsten carbide claddings performed well, with
AFRs from 80 to 157. Solid tungsten carbide provided the highest abrasion resistance, with an AFR of 272, while
carbon steel, AR 400 and chrome carbide weld overlay offer the least abrasion resistance, with AFRs of 4.5, 8 and
33, respectively.

275

250
6000 Rev.
200 RPM
225
30 lb. Load
Abrasion Resistance Factor

200

175

150

125

100

75

50

25

0
1018 AR 400 Chrome WC200 WC210 WC219 Tungsten
Carbide WO Carbide (12%
Co)

Figure 5. Abrasion Resistance per ASTM G65-94, Procedure A

Corrosion Rate

Similar materials were also tested to determine their wear resistance in corrosive laboratory environments. The
same infiltration brazed tungsten carbide claddings were tested, along with 316SS, 17-4 PH and chrome moly steel,
following ASTM G31 testing standards.

Figure 6 depicts the results of the test, which were performed in a solution of 10% hydrochloric acid at 212°F
(100°C). WC 219 had the lowest corrosion rate of 1,034 mils/yr, followed closely by WC210 (1,348 mils/yr) and
WC 200 (1,688 mils/yr). 17-4 PH had a corrosion rate of 14,414 mils/yr and 316 L stainless steel had a corrosion
rate of 19,378 mils/yr. Chrome moly steel performed poorly, with a corrosion rate of 22,264 mils/yr.

25000

22264
10% HCL
20000 212°F (100°C) 19378
Corrosion Rate (mils/yr)

15000 14414

10000

5000

1348 1688
1034

0
WC219 WC210 WC200 17-4 PH 316L SS Chrome Moly
Steel

Figure 6. Corrosion Resistance per ASTM G31

Standardized ASTM testing demonstrates that infiltration brazed tungsten carbide claddings provide high levels of
erosion, corrosion and abrasion protection within controlled laboratory settings. Similar results have been
confirmed outside of the laboratory, in field applications exposed to a variety of wear mechanisms.

REAL-WORLD FIELD APPLICATIONS

Infiltration brazed tungsten carbide cladding is proven to be superior not only in standardized laboratory tests, but
also in real-world erosive environments that cannot be replicated in a laboratory. The cladding has found success in
several industry applications, including protecting induced draft fans, pump impellers, suction heads and casings and
various conveyance components.

NorskeCanada, Port Alberni Division -- Induced Draft Fan

NorskeCanada’s Port Alberni Division began detecting decreased productivity from their power boiler with a
reduction in their induced draft (ID) fan capacity (3). An inspection revealed that the highly erosive fly ash passing
through the fan created extreme wear to the outer portions of the fan blades.

The mill experimented with protecting the fan with chrome carbide weld overlay (see Figure 7). After ten months in
operation, the blades almost completely wore through, causing the fan to miss required boiler loading and forcing
the plant to burn more expensive natural gas. This cost the mill an additional $150,000 in fuel costs over a two
month period.

In an attempt to decrease costs associated with reduced fan efficiency and downtime, and to extend the useful life of
the ID fan to two years the plant installed fan liners, rib plates and side plates clad with infiltration brazed tungsten
carbide. These liners maintained optimal fan capacity through 12 months of continuous operation (see Figure. 8).
 The mill expanded their use of the cladding the following year,
installing second generation fan liners. The entire fan liner was
clad with a 1mm (0.040″) thick application of brazed tungsten
carbide, with the high wear portion of the fan receiving an
additional 1mm (0.040″) thick application. Due to the predictable
wear rate associated with brazed tungsten carbide cladding, it is
expected that the double-clad fan liner will perform at ideal
efficiency for at least two years.

As a result, it is anticipated that the mill will begin replacing the

power boiler ID fan once every other year instead of annually,
Figure 7. Port Alberni fan protected with chrome
carbide weld overlay after 12 months in operation
resulting in a $150,000 biannual savings in maintenance costs.

The NorskeCanada Port Alberni ID fan experiment is one

example of the real-world wear protection success of brazed
tungsten carbide cladding in severe erosive environments. Port
Alberni improved their power generation productivity and has
plans to enhance other paper production processes through the
use of this cladding. Similar results have been illustrated in other
paper mill applications, including pump components.

Paper Mill -- Impeller, Suction Head and Casing

An undisclosed paper mill began experiencing severe wear on

their pump impeller, suction head and casing installed at the
Figure 8. Fan protected with infiltration brazed tungsten underflow of a white liquor clarifier. The pump operates in an
carbide cladding after 12 months in operation
environment that has a 14 pH white liquor solution with forty
percent solids. The pumps are designed are operate in tandem with a redundant pump, not in operation for
maintenance and service purposes. The non-clad pumps, with a cast 316SS construction, are replaced
approximately every six months, with an average run time of three months.

The mill tested the erosion resistance of infiltration brazed tungsten carbide by cladding two Worthington 90cm (3′)
x 60cm (2′) pump components. The mill clad their impeller, suction head and pump casing, with a cladding
thickness of 0.030”. During the cladding process, the pump components are undercut by the appropriate amount to
allow for the increased thickness.

Upon inspection after 13 months in

Figure 9. Pump impeller – 13 months after
installation, run time of 6 – 9 months
mm (0.010″) or wear on the inlet chamfer, as shown in Figure 10, during the same time period. The suction head
also has an expected life of 36 to 48 months.
operation, the pump components had
experienced only minimal wear.
Figures 9 demonstrate the wear found
on the pump impeller. After a run
time of six to nine months, the
impeller suffered cladding wear of
.20 mm (0.008″) to .25 mm (0.010″)
on the center impeller tips. It was
determined that the cladding’s
expected life was 36 to 48 months.
Figure 10. Pump suction head – 13 months
The pump suction head also
after installation, run time of 6 – 9 months
experienced .20 mm (0.008″) to .25
The wear protection provided by the infiltration brazed tungsten carbide cladding increased the mill’s pump
component life from six months to over 36 months, six times longer than the unprotected parts. Because of this
success, the mill plans on expanding the cladding application to other high-wear mill components.

Infiltration brazed tungsten carbide claddings have also found success in a variety of other industries and
applications. The cladding has successfully increased the life of conveyance components across many industries.

Solvay Advanced Polymers -- Conveyance Components

The Solvay Advanced Polymers plant in Augusta, Georgia extrudes, pelletizes and packages polymers for advanced
industrial applications. The most abrasive products that the plant produces are AMODEL polyphthalamide pellets,
which are composed of up to 50% glass. The high-velocity pellets are conveyed through hundreds of feet of
equipment, wearing through line piping and causing severe pipe and elbow blowouts. The abrasive pellets travel up
to 25.4 m/s through piping straight sections and around elbows, which are particularly susceptible to blowouts, as
shown in Figure 11.

Undetected blowouts cost the plant more than $200,000 annually in

lost product yield, with each hour of undetected blowout costing
$4,000. The plant spent an additional $60,000 a year on labor to
repair the daily equipment blowouts. The blowouts create
significant yield reductions, affect process distributions and cause
safety and housekeeping issues.

Solvay tested several potential solutions with resultant life cycles of

seven days to eighteen months. Among the materials evaluated
were long radius elbows, 316 SS short radius elbows, pocket back
deflection elbows, ceramic backed elbows, glass and glass lined
elbows, chrome plating and tungsten carbide spray coatings.
Figure 11. Worn Conveyance Components before the
Each method produced unacceptable outcomes, including excessive
Installation of Infiltration Brazed Tungsten Carbide
Cladding
pellet degradation and undetectable product contamination. Some
approaches used elbows that required removal and cleaning between product and color changes. These methods
were not feasible because of the large number of elbows installed throughout the system.

The plant also evaluated components lined with infiltration

brazed tungsten carbide cladding. They installed short radius 45°
and 90° clad elbows in the 107 mm (4″), 152 mm (6″) and 203
mm (8″) dilute phase conveyance lines. The elbows performed
well, lasting a minimum of two to three years, with many of the
original elbows still in service.

The plant gradually began cladding additional conveyance system

components. Since the initial installation, Solvay has installed
brazed tungsten carbide clad pneumatic conveying lines (see
Figure 12), downstream pipe sections, diverter valves, extruder
transition chutes, pelletizer strand guides and cyclones. The plant
continues to install additional clad parts and keeps spare Figure 12. Conveyance Lines Protected with Infiltration
components on hand for field repairs. Brazed Tungsten Carbide Cladding

The plant increased the life of their entire pneumatic conveyance system by installing components clad with
infiltration brazed tungsten carbide. They significantly decreased their number of piping blowouts, reducing their
lost product and maintenance costs, while increasing their productivity.
CONCLUSION

Infiltration brazed tungsten carbide wear protection applied to equipment components can reduce operating and
maintenance costs, reliably extend planned outages and reduce the risk of unscheduled downtime. Real-world field
experiences, along with standardized testing, has determined that infiltration brazed tungsten carbide cladding
outperforms other protection methods in highly erosive, abrasive and corrosive environments.

Standardized erosion testing reveals that a materials erosion resistance is directly related to the size and spacing of
the material’s hard particles and method of application, as well as the characteristics, impact angle, and velocity of
the eroding media. Infiltration brazed tungsten carbide cladding outperformed other common protective materials,
including 1018 low carbon steel, chrome carbide weld overlay, 400 Brinnell heat-treated hard-plate and solid
tungsten carbide in standard ASTM erosion, abrasion, and corrosion tests.

REFERENCES

1 “Standard Test Method for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets”, Annual
book of ASTM Standards, Wear and Erosion; Metal Corrosion“, v. 03.02,West Conshohocken, PA, , pp. 311-
317, 1999.

2 K. Uuemyis, I. Kleis, V. Tumanov and T. Tiideman, translated from Poroshkovaya Metallurtiya, no. 3, (135)
Appeared in Siviet Powder Metallurgy and Metal Ceramics, pp. 248-250, July 1972.

3 Jennifer Broadwater, Chad Juliot and Andreas Weckesser. “Improving Mill Productivity with Advanced Wear
Protection Solutions.” Presented at TAPPI Fall Technical Conference, 2004.

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