| Welding process | Mode of application | Form of hardfacing alloy | Weld-metal dilution, % | Deposition kg/h | lb/h |
Minumum thickness(a) mm | in |
Deposit efficiency, % |
|---|---|---|---|---|---|---|
| OAW | Manual | Bare cast rod, tubular rod | 1-10 | 0.5-2 | 1-4 | 0.8 | 1/32 | 100 |
| OAW | Manual | Powder | 1-10 | 0.5-2 | 1-4 | 0.8 | 1/32 | 85-95 |
| OAW | Automatic | Extra-long bare cast rod, tubular wire | 1-10 | 0.5-7 | 1-15 | 0.8 | 1/32 | 100 |
| SMAW | Manual | Flux-covered cast rod, flux-covered tubular rod | 10-20 | 0.5-5 | 1-12 | 3.2 | 1/8 | 65 |
| Open arc | Semiautomatic | Alloy-cored tubular wire | 15-40 | 2-11 | 5-25 | 3.2 | 1/8 | 80-85 |
| Open arc | Automatic | Alloy-cored tubular wire | 15-40 | 2-11 | 5-25 | 3.2 | 1/8 | 80-85 |
| GTAW | Manual | Bare cast rod, tubular rod | 10-20 | 0.5-3 | 1-6 | 2.4 | 3/32 | 98-100 |
| GTAW | Automatic | Various forms(b) | 10-20 | 0.5-5 | 1-10 | 2.4 | 3/32 | 98-100 |
| SAW | Automatic, single wire | Bare tubular wire | 30-60 | 5-11 | 10-25 | 3.2 | 1/8 | 95 |
| SAW | Automatic, multi wire | Bare tubular wire | 15-25 | 11-27 | 25-60 | 4.8 | 3/16 | 95 |
| SAW | Automatic, series arc | Bare tubular wire | 10-25 | 11-16 | 25-35 | 4.8 | 3/16 | 95 |
| PAW | Automatic | Powder(c) | 5-15 | 0.5-7 | 1-15 | 0.8 | 1/32 | 85-95 |
| PAW | Manual | Bare cast rod, tubular rod | 5-15 | 0.5-4 | 1-8 | 2.4 | 3/32 | 98-100 |
| PAW | Automatic | Various forms(b) | 5-15 | 0.5-4 | 1-8 | 2.4 | 3/32 | 98-100 |
| GMAW | Semiautomatic | Alloy-cored tubular wire | 10-40 | 0.9-5 | 2-12 | 1.6 | 1/16 | 90-95 |
| GMAW | Automatic | Alloy-cored tubular wire | 10-40 | 0.9-5 | 2-12 | 1.6 | 1/16 | 90-95 |
| Laser | Automatic | Powder | 1-10 | (d) | 0.13 | 0.005 | 85-95 |
(a)Recommended minimum thickness of deposit. (b)Bare tubular wire; extra-long (2.4m, or 8 ft) bare cast rod; tungsten carbide powder with cast rod or bare tubular wire. (c)With or without tungsten carbide granules. (d)Varies widely depending on powder feed rate and laser input power