Stellite welding is a unique process that allows two dissimilar metals to be joined together in one solid bond. It makes it ideal for applications that require strong connections under extreme conditions.

Stellite alloys display high hardness and corrosion resistance due to the cobalt and chromium content. Because of their extremely high melting points, however, machining these materials is difficult.

How It Works

Stellite welding is a unique metal-joining technique using arc heat sources and laser beams to fuse two dissimilar metals. It creates robust connections to withstand extreme temperatures and environments without compromising performance or durability.

The process involves cleaning the surfaces to be welded, then preheating them until they reach their optimal temperature. Once the two pieces are ready, a filler metal is added to the weld to strengthen it.

The most impressive aspect of stellite welding is that it can form two different types of metals into one solid, seamless bond. It is a significant factor in the success of this particular process, as it allows engineers to design and fabricate products that can withstand extreme conditions while maintaining their integrity and strength. The result is a product that may be used confidently in various applications. It consists of medical gear, engines, and aircraft components.

Preparation

With the aid of stellite welding, two dissimilar metals can be bonded to survive extraordinarily high and low temperatures. This welding is frequently employed in the automotive, aerospace, and medical industries.

Typically, stellite welds are created by joining stainless steel to aluminum. The high melting points of these materials enable them to withstand sweltering temperatures and maintain structural integrity.

The resulting weld metal is also very resistant to corrosion and cavitation. It is the perfect substance for various applications, such as steam valves and pumps.

To produce a wear-resistant coating, the dilution of the stellite alloy must be controlled. It is essential because it can affect both the microstructure and hardness of the cladding coating.

Welding

A welding process that uses two different metals to form a bond, stellite welding creates powerful connections that can withstand various conditions and environments. The process consists of cleaning the surfaces, preheating the metals to a specified temperature, and adding filler material.

A torch melts the metals together during welding and forms a solid bond. The filler metal is then added to the joint, helping to increase the strength of the weld.

Stellite 6 is a cobalt-based alloy with high hardness and excellent wear resistance. It is widely used on steam valves, hot shear blades, hot pressing dies, and pumps for high-temperature liquids.

Post-Weld Processing

Post-welding heat treatment (PWHT) is needed to reduce and re-distribute residual stresses and micro-structural changes that develop in welded materials. These can negatively impact their strength, abrasion, and corrosion resistance.

a) Hydrogen-Induced Cracking: During welding, high levels of ambient hydrogen can permeate the material and cause HIC in the welded area. It can be prevented by heating the welded joint to a high enough temperature after welding to diffuse the hydrogen.

The preheat temperature for post-welding heat treatment must be controlled to an exact level to ensure the welded part is heated to the desired temperature for the required length of time. It can be done by using controllable heating systems with thermocouples that monitor the temperature of the welded part.

The heat-up and cool-down rates of PWHT must also be controlled to ensure that the welded part fully transforms into the desired microstructure. If these rates are fast enough, the weld may be customized, thus not having the selected mechanical properties.