T EC HNI CA L DATA SH E E T
PRODUCT OVERVIEW
Vecalloy 600 is a revolutionary new material
specifically designed as a chromium free and
heat-treatable hardfacing. It provides the best
performance in aggressive environments where
impact and abrasive wear are critical sources of
material failure. By eliminating chromium as an
alloying addition, Vecalloy 600 eliminates liability
from the highly carcinogenic hexavalent chromium
fumes generated when welding chromium bearing
materials.
In terms of wear resistance, the high density of
complex borides and vanadium carbides in a
martensitic matrix allow it to compete with the
wear performance of WC/Ni overlays at a lower
price point. The extremely fine lamellar structure
of the complex borides and the spherical
morphology of the vanadium carbides allow for
impact performance 20X that of WC/Ni, and more
than 4X compared to both chromium carbide
overlays (CCO) and nanostructure forming steels.
Vecalloy 600 is heat-treatable, meaning it
preserves excellent performance before and after
standard quench and temper heat treatments.
Vecalloy 600 is patent pending.
DESIGN APPROACH
The design process for Vecalloy 600 and all SCOPERTA materials involves a proprietary high
throughput computational metallurgical process to evaluate millions of candidate alloy compositions.
Potential candidates are then experimentally evaluated using an advanced screening process where
both properties and alloy microstructure are measured.
The combined computational and experimental approach allows SCOPERTA to rapidly design the final
material with a much better accuracy than conventional experiment-based methodologies.
VECALLOY 600 PERFORMANCE
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ASTM G65A: 0.04 – 0.09 grams lost
(5 mm3 – 11 mm3 )
(low stress abrasion)
Hardness: 64.5-68 HRC
Impact Resistance: >10,000 20J
Impacts to Failure
Hard Boride/Carbide Fraction: ~33%
Vecalloy 600
at
1,000X
Double-layer welding of Vecalloy 600
WIRE is NOT recommended.
11760 Sorrento Valley Road, Suite D, San Diego CA 92121 USA
Phone (858) 704-4013 Fax (858) 704-4014
Justin Cheney, PH. D
[email protected]
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T EC HNI CA L DATA SH E E T
VECALLOY 600 OUTPERFORMS CONVENTIONAL HARDFACING
Vecalloy 600 uniquely pairs the toughness required for high impact applications with high wear
resistance to rival the best coatings available. It achieves these typically discordant properties by
forming a high fraction of tough, lamellar complex borides while avoiding long needle-like particles
known to cause problematic embrittlement in chromium carbide type overlays and many nanostructured
steel alloys.
WHY VECALLOY 600 OUTPERFORMS WC/Ni PTA & CHROMIUM CARBIDE
1.
Homogeneity: WC/Ni PTA coatings involve depositing two separate materials
simultaneously; a Ni matrix and tungsten carbide (WC) particles. This results in poor
performance due to undesirable settling and dissolution during welding. In contrast,
Vecalloy 600 is deposited as a single alloy with carbides and borides thermodynamically
driven to precipitate homogeneously throughout the weld thickness.
2.
Fine-Scale Microstructure: WC/Ni PTA and chromium carbide coatings contain carbide
particles on the order of 50 to >250 microns in size. In contrast, the carbides and borides
in Vecalloy 600 range in size from 1 to 10 microns. Computational metallurgy allows us to
design these phases to grow from the liquid at a small and consistent size, shape, and
distribution. This fine scale microstructure has many beneficial effects such as preventing
small sand particles from attacking the matrix directly and distributing thermal stresses
more evenly upon cooling. However, perhaps the most important benefit of the Vecalloy
600 microstructure is the ability to withstand impact and high stresses. Almost every
application which is commonly understood to be an abrasive environment is also an
environment containing high stress and significant levels of impact. Vecalloy 600 provides
the best performance of any hardfacing in high impact, high abrasion applications. 3.
Matrix Hardness: High stress gouging which occurs in many applications such as ground
engaging tools is capable of deforming a soft matrix and essentially machining away any
carbide particles. WC/Ni is very susceptible to this form of damage due to the soft Nickel
matrix. Vecalloy 600, however, is engineered to form a hard martensite matrix and is much
more resistant to this form of damage.
For additional and more detailed technical information please contact:
SCOPERTA at [email protected]
11760 Sorrento Valley Road, Suite D, San Diego CA 92121 USA
Phone (858) 704-4013 Fax (858) 704-4014
Justin Cheney, PH. D
[email protected]
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T EC HNI CA L DATA SH E E T
WHY VECALLOY 600 OUTPERFORMS WC/Ni PTA & CHROMIUM CARBIDE (cont’d)
In the micrograph (right) of WC/Ni PTA, the WC
particles are clumped together in some areas of
the weld and some sections are free of WC
particles. In contrast, the carbide spacing is
thermodynamically driven to a very precise
spacing in the Vecalloy 600 weld. (below, right)
Carbide
Depleted
Carbide
Rich
Notice too, large cracks (highlighted by the
Crack white arrow) running through the
microstructure of the WC/Ni PTA coating.
Crack
Large carbides can be seen below in the WC/Ni
PTA micrograph, but at 500X the hard-phases in
Vecalloy 600 are very small.
WC/Ni PTA
at
25X
WC/Ni PTA
at
500X
Vecalloy 600
at
500X
For additional and more detailed technical information please contact:
SCOPERTA at [email protected]
11760 Sorrento Valley Road, Suite D, San Diego CA 92121 USA
Phone (858) 704-4013 Fax (858) 704-4014
Justin Cheney, PH. D
[email protected]
3 of 8
T EC HNI CA L DATA SH E E T
WHY IMPACT RESISTANCE MATTERS
Many people are surprised to see that despite Vecalloy 600’s nearly equal wear resistance
compared to WC/Ni PTA coatings, Vecalloy 600 significantly outlasts WC/Ni PTA in
actual application. The answer lies in the revolutionary improvement in impact resistance.
While WC/Ni PTA is well known as the standard
for abrasion resistance under ASTM G65 testing,
relatively low levels of impact can generate
cracks and significant levels of material loss.
When subjected to repeated 20J impacts,
Vecalloy 600 lasts 4X as long as the most impact
resistant chrome carbide and 30X as long as WC/
N i P TA . T h i s p a r t i c u l a r i m p a c t t e s t i s
standardized to 20J of impact energy, the
amount of energy developed by dropping a 2 kg
rock a distance of 1m. It stands to reason that
many more applications should consider the use
of coating solutions with better impact
resistance.
As shown in the diagram below, when subjected
to 30 minutes of wear (ASTM G65) Vecalloy 600
c o m p e t e s c l o s e l y w i t h W C / N i P TA a n d
outperforms chrome carbide and nanostructured
hardfacing.
Impact and Abrasion Testing Results of Wear Resistant Coatings
ASTM G65 (Volume Loss, mm3)
Average Impacts Until Failure @ 20J
6
12,000
13
19
25
32
38
Vecalloy 810 OA
Vecalloy 700/710 MIG, OA, SA
(Mn Steel Compatible, Non-Magnetic)
(Highest Impact Resistance)
10,000
Vecalloy 600 MIG, OA
Vecalloy 800 PTA / Laser
(Cr-Free, Heat Treat Compatible)
(Mn Steel Compatible, Non-Magnetic)
8,000
Vecalloy 600 PTA / Laser
Vecalloy 700 PTA / Laser
(Cr-Free, Heat Treat Compatible)
(Highest Impact Resistance)
6,000
Mass and
Volume Scales
Equivalent at
Vecalloy Density
Vecalloy 752
(Proven Gouging Resistance)
4,000
2,000
0
Nanostructured
60/40
Alloys
WC/Ni PTA
mm3 loss
g loss
0.00
0.05
0.10
Chrominum Carbide
Overlays
0.15
0.20
0.25
0.30
ASTM G65 (Mass Loss, grams)
For additional and more detailed technical information please contact:
SCOPERTA at [email protected]
11760 Sorrento Valley Road, Suite D, San Diego CA 92121 USA
Phone (858) 704-4013 Fax (858) 704-4014
Justin Cheney, PH. D
[email protected]
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T EC HNI CA L DATA SH E E T
VECALLOY 600 COST, PROCESS & PRODUCTIVITY ADVANTAGES
Vecalloy 600 delivers WC/Ni PTA performance with the cost and productivity advantages
of iron-based alloys and MIG (GMAW) welding.
The material properties of Vecalloy 600 allow for
unique advantages in cost and productivity that
expand the use of extremely abrasion resistant
materials into wider markets. Vecalloy 600 is an
iron-based alloy resulting in significant material
cost savings compared to WC/Ni products. Further,
MIG welded Vecalloy 600 has a ~99% deposit
efficiency while WC/Ni PTA has a 70% deposit
efficiency. This means that 1.4 kg of WC/Ni must
be purchased for every 1 kg deposited.
Vecalloy 600, because it is iron-based, has a lower
density than WC/Ni, this results in further cost
savings.
Consider the manufacture of a 12” x 12” (300mm x 300mm) wear plate with a ¼” (6mm) overlay.
The production of this plate would require half the amount of material by weight when using Vecalloy
600 PTA as opposed to WC/Ni PTA.
This immediately results in significant cost savings, in addition to significantly reducing the final weight of
the component.
In addition to direct material cost, Vecalloy 600 has excellent performance when applied via a wire welding
process. This allows a far higher deposition rate than WC/Ni PTA, dramatically improving productivity.
For example, WC/Ni PTA is typically deposited at a rate of 11 in3/hr (180 cm3/hr). Vecalloy 600 is
typically deposited at a rate of 40 in3/hr (655 cm3/hr), almost 4 times as fast!
For additional and more detailed technical information please contact:
SCOPERTA at [email protected]
11760 Sorrento Valley Road, Suite D, San Diego CA 92121 USA
Phone (858) 704-4013 Fax (858) 704-4014
Justin Cheney, PH. D
[email protected]
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T EC HNI CA L DATA SH E E T
SUGGESTED APPLICATIONS
Vecalloy 600 coatings are suggested for use in any applications where abrasion resistance is required. The
revolutionary improvement in impact resistance and toughness will typically result in an extended lifetime
over WC PTA and Chromium Carbide coatings.
Specific applications include:
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Shaker Screens
Grader Blades and other Ground Engaging Tools
Chute Blocks
Wear Plate
Mill Liners
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Slurry Pipe
Shovel Wear Packages
Communition
Other Mining Applications
HOW TO USE VECALLOY 600
Vecalloy 600 is currently available as cored wire in 0.045” (1.1 mm), and 0.063” (1.6 mm) for GMAW and
in 0.109” (2.8 mm) for open arc welding. Additional welding wire diameters, PTA powder, and laser powder
are available upon request. The suggested welding parameters and expected results for Vecalloy 600 are
provided on this page and the following page.
Please note: for cored wire applications, Vecalloy 600 can be deposited as stringer beads or oscillated beads. However, it is recommended that Vecalloy 600 cored wire only be welded as a single layer deposit. Multiple
layer deposits can reduce the impact resistance of the overlay.
Preheating Guidelines, Interpass Temperature, and Post Weld Heat Treatment:
Preheat temperatures should be done in accordance to the substrate requirements to minimize the heat
affected zone. Allow the part to cool below 500°F before welding Vecalloy 600. Vecalloy 600 can be
austenitized (850° – 950°C) and water or oil quenched without significant decrease in properties. Vecalloy
600 can also be tempered up to 150°C after quenching.
Vecalloy 600 0.045-inch & 0.063-inch GMAW WELDING PARAMETERS
Wire Diameter
Current
Desired Weld Thickness
Voltage
Amperage
Shielding Gas
0.045 in (1.1 mm)
DCEP
3 - 6 mm
25 - 27 V
~155A
0.063 in (1.6 mm)
DCEP
3 - 8 mm
25.5 - 27 V
~225A
Ar 98%/O2 2%
Ar 98%/O2 2%
Stickout
Preheat
Interpass Temperature
.075 in (19 mm)
*see Preheating Guidelines pg. 6
1.125 in (28 mm)
*see Preheating Guidelines pg. 6
≤300°F
Torch Drag Angle
5 - 15°
Expected Hardness
65 - 68 HRc
Expected ASTM G65 mass loss 0.07 - 0.09 g
≤300°F
5 - 15°
65 - 68 HRc
0.07 - 0.09 g
Acceptable Dilution
5 - 15%
15 - 20%
For application specific guidance on proper welding procedures please contact:
SCOPERTA at [email protected]
11760 Sorrento Valley Road, Suite D, San Diego CA 92121 USA
Phone (858) 704-4013 Fax (858) 704-4014
Justin Cheney, PH. D
[email protected]
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T EC HNI CA L DATA SH E E T
HOW TO USE VECALLOY 600 (cont’d)
Vecalloy 600 7/64-inch OPEN ARC WELDING PARAMETERS
Wire Diameter
0.109 in (2.8 mm)
Current
DCEP
Desired Weld Thickness
6 - 10 mm
Voltage
25 - 26.5 V
Amperage
~430
Shielding Gas
N/A
Stickout
1.5 in (38 mm)
Preheat
*see Preheating Guidelines pg. 6
Torch Drag Angle
5 - 15°
Expected Hardness
64.5 - 68 HRc
Expected ASTM G65 mass loss
0.065 - 0.09 g
Acceptable Dilution
15 - 40%
Vecalloy 600 LASER WELDING PARAMETERS
These parameters were developed using a Coherent 4000L & Coherent 8000L. Please note that optimum
parameters can be very different with differing laser equipment, and these parameters can only serve as a
starting point. Laser welds can be deposited with multiple layers to achieve the desired total thickness. A
24mm wide beam size can be used to deposit a 5-6mm thick single-pass weld.
Beam Size
6x6 mm
24x6mm
Shielding Gas
Argon
Argon
Power
4kW
7.5kW
Powder Feed
35 g / min
80 g / min
Expected Hardness
~68 - 70 HRC
~68 - 70 HRC
For application specific guidance on proper welding procedures
or more detailed technical information please contact:
SCOPERTA at [email protected]
11760 Sorrento Valley Road, Suite D, San Diego CA 92121 USA
Phone (858) 704-4013 Fax (858) 704-4014
Justin Cheney, PH. D
[email protected]
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T EC HNI CA L DATA SH E E T
HOW TO USE VECALLOY 600 (cont’d)
Vecalloy 600 PLASMA TRANSFER ARC (PTA) WELDING PARAMETERS
Please note that parameters can be very different with differing PTA equipment, and these parameters
can only serve as a starting point. PTA welds can be welded with up to (2) layers to achieve the desired
total thickness.
Powder Size
53-150µm
Voltage
28 V
Amperage
180 A
Expected Thickness
~3 mm
Expected Hardness
~66 - 68 HRC
Expected ASTM G65A
0.048 - 0.6 grams lost
For application specific guidance on proper welding procedures
or more detailed technical information please contact:
SCOPERTA at [email protected]
11760 Sorrento Valley Road, Suite D, San Diego CA 92121 USA
Phone (858) 704-4013 Fax (858) 704-4014
Justin Cheney, PH. D
[email protected]
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