WEAR-ARC Covered Electrodes Introduction Surfacing is the application of wear-

resistant alloys to metal parts subject to destructive wear caused by abrasion, impact,
compression, heat, or corrosion. The Wear-Arc electrodes are designed for manual arc
welding for surfacing parts. Two types of overlay alloys are recommended to correct
destructive wear patterns: Buildup Alloys Because hardsurfacing alloys are limited by
maximum thickness of deposit, badly worn parts must be built up prior to depositing the
wear-resistant material. Wear-Arc 3 IP, Nickel Manganese, and WH are designed for
buildup applications. These alloys possess good deformation resistance and provide a
strong bond with the base metal. This helps to prevent roll-over or spalling and provides a
sound base for hardsurfacing. Hardsurfacing Alloys Hardsurfacing alloys are designed to
provide maximum resistance to specific wear factors or combination of wear factors. The
performance of these alloys is in direct relation to the amount of carbide forming
elements present in combination with carbon. The carbon reacts with the carbide forming
elementschromium, tungsten, molybdenum, etc.creating hard carbides from which
the overlay material derives its wear resistance. These carbides are evenly distributed in a
matrix and as the ratio of carbides to matrix increases, abrasion resistance increases and
toughness or ductility decreases. The chart on the following page shows the relative
impact resistance or ductility and the abrasion or wear resistance of the Wear-Arc line.

Hardsurfacing Covered Electrodes Wear-Arc 3 IP AC/DCEP (Electrode Positive)

Electrode Imprint Marking: 3 IP Buildup Alloy Carbon Steels, Low Alloy Steels,
Abrasion-Resistant Steels Description: Wear-Arc 3 IP weld metal provides excellent
resistance to wear caused by heavy impact and compressive loads, and is most suitable as
a base alloy for hardsurfacing overlays. Wear-Arc 3 IP should be used where maximum
machinability of a surface deposit is desired and as the final overlay. The ductility and
compressive strength of Wear-Arc 3 IP weld metal is adequate for the wear problem of
many applications. Typical applications are: steel mill wobblers and coupling boxes,
bearing journals, steel mill roll necks and ends, forging hammer dies, and all carbon steel
parts requiring buildup prior to hardsurfacing. Procedure: Wear-Arc 3 IP has superior
welding characteristics in all positions. Because of the iron powder in the coating, higher
current settings may be used than with conventional electrodes. Area Covered per Pound,
1/8" (3.2 mm) Depth 24-25 in.2 (155-161 cm2)

Typical Mechanical Properties As Welded Yield Strength, psi (MPa) 91,500 (631) Tensile
Strength, psi (MPa) 101,750 (702) % Elongation in 2" (51 mm) 24 % Reduction in Area
64 Hardness 29 Rc* *Two Layers weaving on 1020 Steel Weld deposits can be cut with
oxy-acetylene torch or by air carbon-arc cutting. Typical Undiluted Weld Metal Analysis
(%) C Mn Si Cr Mo 0.20 Max. 0.09 0.70 2.30 1.10 Properties of Deposited Weld Metal:
The chromium and molybdenum alloy balance imparts impact and compression
resistance, as well as considerable wear resistance to the weld metal in all thicknesses of
buildup. Standard Diameters 1/8" (3.2 mm), 5/32" (4.0 mm), 3/16" (4.8 mm), 1/4" (6.4
mm)
Typical Mechanical Properties As Welded Yield Strength, psi (MPa) 91,500 (631) Tensile
Strength, psi (MPa) 101,750 (702) % Elongation in 2" (51 mm) 24 % Reduction in Area
64 Hardness 29 Rc* *Two Layers weaving on 1020 Steel Weld deposits can be cut with
oxy-acetylene torch or by air carbon-arc cutting. Typical Undiluted Weld Metal Analysis
(%) C Mn Si Cr Mo 0.20 Max. 0.09 0.70 2.30 1.10 Properties of Deposited Weld Metal:
The chromium and molybdenum alloy balance imparts impact and compression
resistance, as well as considerable wear resistance to the weld metal in all thicknesses of
buildup. Standard Diameters 1/8" (3.2 mm), 5/32" (4.0 mm), 3/16" (4.8 mm), 1/4" (6.4
mm)
Typical Mechanical Properties As Welded Yield Strength, psi (MPa) 91,500 (631) Tensile
Strength, psi (MPa) 101,750 (702) % Elongation in 2" (51 mm) 24 % Reduction in Area
64 Hardness 29 Rc* *Two Layers weaving on 1020 Steel Weld deposits can be cut with
oxy-acetylene torch or by air carbon-arc cutting. Typical Undiluted Weld Metal Analysis
(%) C Mn Si Cr Mo 0.20 Max. 0.09 0.70 2.30 1.10 Properties of Deposited Weld Metal:
The chromium and molybdenum alloy balance imparts impact and compression
resistance, as well as considerable wear resistance to the weld metal in all thicknesses of
buildup. Standard Diameters 1/8" (3.2 mm), 5/32" (4.0 mm), 3/16" (4.8 mm), 1/4" (6.4
mm)
C Mn Si N
0.60 14.00 0.55 4.00

Yield Strength, psi (MPa) 62,000 (427)

Tensile Strength, psi (MPa) 116,000 (800) %
Elongation in 2" (51 mm)45
Hardness 90 Rb*
Work-Hardened Hardness 48 Rc*

Hardsurfacing Covered Electrodes Wear-Arc WH No AWS Classification AC/DCEP

(Electrode Positive) Electrode Imprint Marking: WH Buildup Alloy High Strength,
Manganese & Carbon Steels, Attachment Welding, Severe Impact Description: The weld
deposit of Wear-Arc WH is high in alloy content, extremely deformation resistant, and
has 2-4 times greater wear resistance than work-hardened austenitic manganese steel.
WH contains approximately 34% alloy, properly balanced to perform the dual purpose of
a work-hardening, wear-resistant buildup alloy, and also a high strength welding alloy.
The alloy is austenitic and produces tough, crack-resistant welds. Wear-Arc WH produces
a dependable bond to manganese steel. Users of type 308, 309, 310, or 312 stainless steel
electrodes for rebuilding and repair of equipment constructed of manganese steel find
Wear- Arc WH to be a superior electrode for the job. Deposits of Wear-Arc WH, when
subjected to high impact and compressive loads, develop a surface hardness of 48-50
Rockwell C and still retain a tough, resilient, deformation-resistant mass under the work-
hardened surface. Procedure: Wear-Arc WH electrodes are designed for welding with AC
 DCEP (Electrode Positive) in all positions. When welding high-carbon steel, preheat to
300-400F (149-204C). Do not preheat manganese steel. Hold the electrode at an angle
of 15 in the direction of travel with as short an arc as possible without allowing the
coating to touch the weld pool. Stringer beads are preferable. Weaving should be limited
to 2-1/2 times the electrode diameter. Slag should be cleaned thoroughly between passes.
For vertical welding, the electrode should be held perpendicular to the plate using a very
slight oscillation from side to side on the root bead. When welding in the overhead
position, hold a short arc with no oscillation of the electrode.

Area Covered per Pound, 1/8" (3.2 mm) Depth 20-22 in.2 (129-142 cm2) Typical
Mechanical Properties Wear-Arc 14% WH Manganese Weld Metal Steel Plate As Welded
Heat Treated Yield Strength, psi (MPa) 77,000(551) 50,000 (345) Tensile Strength, psi
(MPa) 97,500(672) 86,000 (593) 120,000 (827) % Elongation in 2" (51 mm) 36 35/45
Hardness 23 Rc* 16 Rc Work-Hardened Hardness 48.5 Rc* 48 Rc *Two Layers on 1020
Steel Weld deposits cannot be cut with oxy-acetylene torch or by air carbon-arc cutting.
Typical Undiluted Weld Metal Analysis (%) C Mn Si Cr Ni 0.45 4.25 0.80 19.75 10.00
Standard Diameters 1/8" (3.2 mm), 5/32" (4.0 mm), 3/16" (4.8 mm) Continued on next
page...

Wear-Arc 5 IP No AWS Classification AC/DCEP (Electrode Positive) Electrode Imprint

Marking: 5 IP Hardsurfacing Alloy High impact and moderate abrasion Carbon steels
and low alloy steels Description: Wear-Arc 5 IP is an all-position, low hydrogen
hardsurfacing composite electrode providing sound overlays on carbon and low alloy
steels, as well as many abrasion-resistant steels. Wear-Arc 5 IP is recommended for the
reclamation of parts subject to wear caused by moderate to high impact and moderate
abrasion. Typical applications are: Dipper Shovels Classifier Screens Dipper Lips Bucket
Pins Bulldozer Trunnions Mud Pumps Drag Line Bucket Lips Bucket and Impellers
Procedure: Wear-Arc 5 IP electrodes are designed for welding with AC or DCEP. When
welding out of position, DCEP is preferred. A slight weaving technique may be used.
Typical Mechanical Properties: Deposits are non-machinable, but may be forged at red
temperatures. The deposit is heat treatable and magnetic. Weld deposits can be cut with
oxy-acetylene torch or by air carbon-arc cutting.

Hardness of Deposited Metal: One layer on 1020 mild steel50-55 Rockwell C Two
layers on 1020 mild steel58-60 Rockwell C Typical Chemical Analysis of Weld
Deposit (%) C Mn Si Cr Mo 0.65 1.00 0.80 5.75 0.65 Standard Diameters 1/8" (3.2 mm),
5/32" (4.0 mm), 3/16" (4.8 mm), 1/4" (6.4 mm)

Wear-Arc 6 IP No AWS Classification AC/DC Electrode Imprint Marking: 6 IP

Hardsurfacing Alloy High Abrasion & Light Impact Carbon Steels and Manganese Steels
Description: The iron powder low hydrogen coating of Wear-Arc 6 IP electrodes
promotes good bonds with manganese and carbon steels. Wear-Arc 6 IP is recommended
for the reclamation of parts subject to wear caused by abrasion and light impact. This
electrode is ideal for field work where parts cannot be positioned for downhand welding.
Typical applications are: Shovel buckets and teeth Screens Dragline buckets and teeth
Asphalt mixer paddles Pug mill paddles Crushing equipment Tamping tools Granulators
Truck bodies Trunnions Procedure: Wear-Arc 6 IP provides high deposition rates in all
positions using AC or DC, either polarity. A weaving technique is recommended. Deposit
thickness should be limited to two passes or 1/4" (6.4 mm) maximum.

Area Covered per Pound, 1/8" (3.2 mm) Depth 22-24 in.2 (142-155 cm.2) Typical
Mechanical Properties: Deposits are not machinable and are smooth, requiring a
minimum amount of grinding to bring them to shape. Deposits are not affected by heat
treatment and can be forged at red heat. Weld deposits cannot be cut with oxy-acetylene
torch or by air carbon-arc cutting. Hardness of Deposited Metal: Two layers, weave bead
on 1020 mild steel 56-59 Rockwell C Typical Undiluted Weld Metal Analysis (%) C
Mn Si Cr 3.00 0.80 1.80 6.50 Standard Diameters 1/8" (3.2 mm), 5/32" (4.0 mm), 3/16"
(4.8 mm), 1/4" (6.4 mm)

Wear-Arc 12 IP No AWS Classification AC/DC Electrode Imprint Marking: 12 IP

Hardsurfacing Alloy High Impact & Good Abrasion Resistance Carbon Steels and
Manganese Steels Description: The high alloy content of Wear-Arc 12 IP provides good
resistance to erosion and corrosion. Wear-Arc 12 IP is recommended to prolong the
service life of new and worn parts subject to wear caused by abrasion and impact. Typical
applications are: Dipper teeth and lips Gyratory crusher parts Dragline bucket lips Muller
tires Conveyor bucket lips Impactors Roll crushers Hammer mill parts Procedure: The
iron powder, low hydrogen coating of Wear-Arc 12 IP electrodes provides excellent arc
characteristics and high deposition rates in all positions using AC or DC, either polarity.
Weaving technique or stringer beads may be used. Deposit thickness should be limited to
two passes or 1/4" (6.4 mm). Area Covered per Pound, 1/8" (3.2 mm) Depth 22-24 in.2
(142-155 cm.2)

Typical Mechanical Properties: Check cracks may appear as the deposit stress relieves
itself. These cracks do not impair the wear resistance of the deposit, but do prevent
warpage or distortion of the base metal. Deposits are non- machinable and do not respond
to heat treatment. Weld deposits cannot be cut with oxy-acetylene torch or by air carbon-
arc cutting. Hardness of Deposited Metal: Two layers, weave bead on 1020 mild steel
54-56 Rockwell C Typical Undiluted Weld Metal Analysis (%) C Mn Si Cr Mo 3.50 2.70
1.80 13.00 1.10 Standard Diameters and Packages 1/8" (3.2 mm), 5/32" (4.0 mm), 3/16"
(4.8 mm), 1/4" (6.4 mm)
Wear-Arc 40 No AWS Classification AC/DCEP (Electrode Positive) Electrode Imprint
Marking: 40 Hardsurfacing Alloy Extreme Abrasion & Medium Impact Description:
Wear-Arc 40 has a special core wire and the proper amount of alloys in the coating to
produce a deposit of highly abrasive resistant chrome carbides in a matrix of iron and
chromium. The use of a special core wire gives much better arc action and also allows the
electrode to operate at higher current settings. Deposits resist galling and seizing, and
take a high polish when subject to sliding abrasive action. Wear-Arc 40 is designed for
use on steel mill twist guides, steel mill entry guides, wire guides, conveyor chain, and
 agricultural tools. This electrode also gives excellent service on certain crushing and
quarrying equipment where high abrasive wear is the primary wear factor. This alloy has
excellent hardness at constant temperatures up to about 1000F (538C). In considering
this alloy for a heat and abrasion application, a constant operating temperature must be
estimated. For example, a steel mill guide block surface with Wear-Arc 40 withstands
exposure to intermittent contact with hot billets of bars at temperatures of 1800-2000F
(982-1093C). This is possible because sufficient time elapses between contacts to
prevent a high temperature build-up.

Procedure: Wear-Arc 40 electrodes have good welding characteristics in flat and vertical-
up positions. Weaving technique or stringer beads may be used. Limit deposit thickness
to two passes. Area Covered per Pound, 1/8" (3.2 mm) Depth 20-24 in.2 (129-155
cm.2) Typical Mechanical Properties: The weld metal deposit of Wear-Arc 40 cannot be
forged at any temperature and does not respond to heat treatment. Weld deposits cannot
be cut with oxy-acetylene torch or by air carbon-arc cutting. Hardness of Deposited
Metal: Two layers on mild steel57 Rockwell C Typical Undiluted Weld Metal Analysis
(%) C Mn Si Cr 4.50 0.30 1.80 30.00 Standard Diameters 1/8" (3.2 mm), 5/32" (4.0 mm),
3/16" (4.8 mm), 1/4" (6.4 mm)

WEAR-O-MATIC Semiautomatic Cored Wires Wear-O-Matic cored wires for

semiautomatic application are fabricated tubular wire internally stabilized for good arc
characteristics without the use of shielding gas or submerged arc granular flux. Each of
the grades available has a carefully balanced alloy content to produce specific properties
in the deposited weld metal, which provide the required wear resistance for which each
grade is intended. Manufacturing processes and quality control measures assure uniform
alloy distribution throughout the tubular wire to maintain constant wear-resistant
properties throughout the deposit. Wear-O-Matic wires are manufactured in the 7/64 (2.8
mm) diameter for smooth, even feeding and constant current pick-up at the contact tip.
The following pages list the Wear-O-Matic wires for open arc application with
descriptive information to aid in the selection of alloys for economical hard surfacing.