Abrasive Wear Behavior of Hardfaced En-31 Steel

Balpreet Singha,∗, Sukhpal Singh Chathab , Harish Garga

a Punjab Technical University, Jalandhar, Punjab, India-144601
b Yadavindra College of Engineering, Punjabi University, Guru Kashi Campus, Talwandi Sabo, Punjab, India-151302

Abstract
In the present work the effect of hardfacing on the abrasive wear behaviour of tillage tool (EN-31 steel) has been
investigated. A study was made to compare the microhardness, microstructure and abrasion resistance of base metal as
well as hardfaced specimens. The hardfacing alloys were deposited onto EN-31 carbon steel plates by a manual metal arc
welding (MMAW) method. Two different commercial available hardfacing electrodes (Cr carbide and Fe carbide base)
were used to investigate the effect abrasive wear. The abrasion tests were carried out in rubber wheel abrasion tester
(RWAT) according to the procedure of ASTM G-65 standard. Abrasion behaviour with a RWAT has been examined with
sandy sand and sandy loam abrasives under dry and wet conditions. The estimation of wear behaviour was supported by
microstructural analysis and by microhardness tests. The surface analysis was made using scanning electron microscopy.
It was observed that hardfaced steel has shown better wear behavior than the bare steel under both the dry and wet
condition. Among the hardfacings, the Cr-carbide based hardfacing has shown better resistance to abrasive wear. Further
it is observed that bare and hardfaced steel has experienced higher wear rate under dry condition of testing as compare
to wet condition.
Keywords: Abrasive wear, Hardfacing, Microhardness, Microstructure .

1. Introduction research conducted in Turkey, it has been found that

there is on an average 2.7–6.3 gkm−1 (90–210 gha−1 ) of
Wear is a phenomenon of material removal from one wear in a ploughshare, 2.5–5 gkm−1 (60–120 gha−1 ) wear
or both the solid surfaces in solid state contact, due to in cultivator sweeps and 0.15–0.32 gkm−1 (30–70 gha−1 )
sliding and rolling motion with each other. It is a severe wear in harrow tines. Chisel ploughshare wear has been
problem in the excavation, earth moving and agriculture found as 6.94–11.94 gkm−1 (23–40 gha−1 ) [5]. Wear on
equipments etc [1]. The high wear rate of ground parts of a plough body, more systematically, depends on
engaging tools make a cause of huge loss of material, their thermal processing and shape, the tillage
recurring labour, downtime and replacement costs of conditions, as plough area, plough speed and tillage
worn out parts. Due to loss of material lifespan of the depth, the normal forces between the soil and the
tool will also affect [2]. There are many types of wear surfaces of the plough area, the proportion, hardness,
and also many factors that affect its severity and rate. sharpness and shape of soil particles, the moisture
Numerous types of wear have been documented, e.g. content of the soil, the density and mechanical properties
sliding wear, abrasive wear, erosive wear and chemically of the soil (hardness, shear strength and brittleness) and
assisted fretting wear, surface fatigue [3]. In engineering environmental effects and weather changes [6]. In the
industries, abrasive wear is probably the most significant present work effect of bare as well as hardfacings on the
cause of mechanical damage of equipment components abrasive wear behavior of EN-31 steel also been
coming in contact with abrasive bodies. Generally investigated under the wet and dry conditions using
abrasive wear occurs when hard abrasive particles go different types of sand namely sandy and sandy loam.
through the components and make a cause of material
loss. The components of machines working under severe
conditions, like a fluid pump handling slurry, the soil 2. Experimentation
engaging tools of the earthmover machinery, and various
agricultural equipments that are subjected to abrasive 2.1. Substrate
wear [4]. The cost of abrasive wear losses is high and has Generally, the material engaged in farming tools and
been estimated as ranging from 1 to 4% in the gross equipments is carbon steel. EN-31 steel, equipped with
national product of an industrialized nation. In a hardness and toughness, finds wide application to resist
several types of wear mechanisms. For instance, EN-31
∗ Corresponding steel has also been used for parts engaged in agricultural
Author
Email address: [email protected] (Balpreet Singh) equipments and ploughshare, in opposition to harsh
Singh, Chatha, and Garg Abrasive Wear Behavior of Hardfaced En-31 Steel

conditions such as abrasion wear. In the present work, motor. At the end of the shaking operation, the sieves
EN-31 steel is used to analyse the tribological behaviour were taken out and sand retained on each is weighted.
of base and hardfaced material against three-body wear Each weight was converted into percentage. Each
mechanism. EN-31 steel had been used as substrate percentage multiplied by a weighing factor and these
material. The raw material for the present research work were added to get the sum of product. After calculating
EN-31 was purchased from B.K. steel, Ludhiana the grain fineness number of sandy sand and sandy loam
(Punjab) and the specimens for various investigations sand was found to be 51.72 and 51.79 respectively.
were prepared as per the ASTM G65 standards. The
composition of the raw material was analyzed with 2.4. Abrasion Test
optical emission spectroscope (OES) at R&D, Ludhiana The rubber wheel abrasion test (RWAT) as described
to ensure the type of material has composition mentioned in ASTM standard G-65 has been used to evaluate the
in Table 1. A plate having dimensions 228mm × 152mm abrasive wear behaviour of material under three-body
× 13mm which was hardfaced and specimens for testing conditions. The apparatus consists of plane specimen
were prepared from the same plate after being hardfaced, who is loaded against the rotating rubber wheel made of
having dimensions as 25mm in width, 76mm length chloro-butyl rubber. The rubber wheel abrasion test
followed by 13mm of thickness. produces soft abrasion, where the abrasive particles
generally remain intact following the abrasion process.
Table 1: Composition of EN-31 Steel.
The wheel is kept on constant speed and load of 200rpm
Steel C S Si Mn Cr Fe and 20N respectively. In the present study the concern is
EN31 1.01 0.045 0.055 0.52 1.16 Bal of flow rate as well as the types of sand. In the present
study flow rate of sand is taken as 100gm/min and
200gm/min. The time taken for each experiment was 10
2.2. Hardfacing Alloy minute. Further the study is performed under both the
dry and wet condition so as to study the effect of
In this work Chromium carbide based, denoted as
moisture content in the soil. The specimens were
HF1 (Hardfacing1) and Iron carbide based, denoted as
weighted before and after the test were performed so as
HF2 (Hardfacing2), which are easily and commercially
to check the weight loss due to wear.
available were used to hardface the substrate material.
The composition of the electrodes used for welding is
given in Table 2. Process to be used for the deposition of
electrodes to the substrate was Manual Metal arc
Welding process before hardfacing, substrate was ground
and cleaned with acetone. To ensure the dryness of
electrodes, they were baked in the electric oven at 100o C
Figure 1: Particle Size Distributions of Sand Particle.
for about 2 hours. In the present work, 2mm thick layer
was deposited over the substrate material with 25%
overlapping of the deposited layers. Parameters employed
for manual metal arc welding are mentioned in Table 3. 3. Results and Discussions

2.3. Selection and preparation of Sand 3.1. Microhardness Analysis

Abrasive particle used in experimental work was two The Vickers’s microhardness of clad layer over the
types of field sand. Two type sand namely sandy (S1) cross-section has been evaluated. The microhardness
and sandy loam (S2) were selected to examine the values of the hardfacings on the given steel have been
abrasive wear behaviour on substrate as well as measured across the hardfacing- substrate interface and
hardfaced samples. The sand particles used as abrasive plotted in Fig. 2 as a function of distance from the
particles were collected from two different field locations. hardfacing-substrate interface. The substrate material
Physical properties of selected sands are shown in Table (EN-31 Steel) has lesser hardness as compared to the
4. The collected sand was dried to remove the traces of hardfacings. Average value of microhardness of the base
moisture present in it. Sand was sieved to remove gravel material has been found to be 119.6 Hv. Among the two
content so as to prevent choking of sand flow nozzle. The hardfacings, the average microhardness value of HF1
particle size distribution of the dry sand is performed by hardfacing (183.3 Hv) is slightly higher than HF2
using vibratory sand seiver as shown in Fig. 1. The test hardfacing (177.1 Hv). It is observed that the
apparatus consists of a set of graded sieves placed one microhardness of the base metal is slightly higher near
above the other. The coarsest sieve at the top and the the fusion line, which may be due the dilution. Further
finest sieve at the bottom, next to the pan, the sand was for for both of the hardfacing, the value of microhardness
put into the top sieve and the set of sieve shaken has been found to be less near the fusion line, which may
continuously for 20 minutes with the help of electric be due to dilution i.e. dilution of alloying elements from
International Journal of Surface Engineering & Materials Technology, Vol. 7, No. 1, January-June 2017, ISSN: 2249-7250 23
Singh, Chatha, and Garg Abrasive Wear Behavior of Hardfaced En-31 Steel

Table 2: Chemical composition of electrodes (in weight percentages)

C Si Mn Cr Mo V Ni W Nb Fe
Hardfacing 1 3.2 1 1 29 0.7 0.2 0.35 - - Bal
Hardfacing 2 4.4 1.2 0.3 4.5 6.5 1.5 - 2.2 5.5 Bal

Table 3: Welding Parameters

Electrode type Electrode diameter Arc Voltage Electrode Polarity Welding Current
Hardfacing 1 3.2mm 27 +ve 125
Hardfacing 2 3.2mm 27 +ve 125

Table 4: Physical properties of sands them [8]. Fig. 3(b) shows cross-sectional microstructure
Texture % of EN-31 steel with hardfacing (HF1). According to the
Texture Class microstructure self cooled and massive carbide dendritic
Sand Clay Silt
network of alloy carbides was observed. The heat affected
Sandy Sand 90 4.74 4 zone is observed to have fine distribution of pearlite and
Sandy Loam Sand 55 13 33 ferrite grain structure. Also there is grain coarsening
observed in different places. The weldment region
observed to have fine microstructure than the substrate
the hardfacing towards the substrate material and metal thus showing a greater value of microhardness at
vice-versa. In addition, higher microhardness at the top the top surface of weldment region. A massive carbide
of hardfacing, in case of both of the hardfacings i.e. HF1 dendritic network of alloy carbides was observed. The
hardfacing and HF2 hardfacing respectively, may be presence of carbon results in formation of hypoeutectic,
attributed due to more presence of hard carbide particles eutectic, and hypereutectic structures which enhances
towards the top of the weld surface. While welding, in abrasion wears resistance properties [9]. These carbides
the weld pool, the carbides being low in density move can form relatively large micro-constituents, which
towards the top surface of the weld pool, resulting in provide enhanced abrasion wear resistance. These rich
higher density of carbides towards the top surface. chromium alloys make excellent wear resistance, also
Similar results have also been observed by Gupta and justified in microhardness as the value suddenly shown an
sharma [7]. increase in hardness, also these carbides are an effective
barriers against the sliding wear. The structure is
self-cooled hence it possesses high value of hardness,
which is evident in the hardness value. Microstructure
shows the excellent bonding between hardfacing and base
metal. Both hardness and shear strength are supposed to
increase with increasing bonding temperature as well as
time, which is attributed to higher rate of phase
transformations and development of new phases [10]. Fig.
Figure 2: Microhardness profile of EN-31 Steel hardfaced with HI 3(c) presents the cross-sectional microstructure of
and H2 Hardfacing. hardfacing (HF2) deposited on the substrate metal.
Microstructure shows light as well as dark grey dendritic
structure. Microstructure reveals slightly coarse grain
3.2. Microstructure Analysis pearlitic ferritic structure. The presence of coarse grain
Metallographic study of base as well as hardfaced enhances the hardness of the heat affected zone which is
deposits carried out using optical microscope after seen in the microhardness results (Fig. 2). In addition,
etching the surface of the specimen with ethanol. Fig. the distribution pearlite adversely influences the
3(a) shows the microstructures of substrate material toughness of ferritic weld metal. Moreover, the hardness
(EN-31) at 100X. Microstructure shows the fine near the heat affected zone on the weldment has a sudden
distribution of ferrite grains, along with uniform pearlite drop in its value which is the result of fine distribution of
grain. These fine distributions enhance the property of pearlite which was observed in the base metal. Similarly,
high value of hardness as well as the ductility of the the same type of fluctuation was found on the other side
material. Also this arrangement of grains enriches the of the heat affected zone, after which the hardness value
metal in opposition to abrasion wear occurring in tools consistently decreases towards base metal.
used in making agricultural equipments, by increasing its
toughness which is another major property required in

International Journal of Surface Engineering & Materials Technology, Vol. 7, No. 1, January-June 2017, ISSN: 2249-7250 24
Singh, Chatha, and Garg Abrasive Wear Behavior of Hardfaced En-31 Steel

20N load and flow rate of 100g/min is shown in Fig. 5(c).

SEM morphology reveals about the wear mechanism of
the specimen under the given testing condition. The
grooves are smooth and continue and their depth is not
high enough. The grooves are as far from each other.
Somewhere microploughing mechanism also examined
Figure 3: Cross section microstructure of (a) EN-31 steel (b) EN-31
Steel hardfaced with HF1 hardfacing (c) EN-31 steel hardfaced with 3.4. Effect of abrasive particle flow rate
HF2 hardfacing (Original magnification 100X). Among the two testing conditions (dry and wet) all
samples (bare and hardfaced) has shown slight increase
in weight loss with the increase in abrasive particle flow
3.3. Abrasive Wear Behaviour
rate from 100gm/min to 200gm/min as shown in Fig. 6.
Wear has been measured by weighing the specimen Rabinowicz et al. [11] also depicted that for the same
before and after the test so as to know the loss due to abrasive material, the change in wear rate was found to
wear under both the conditions (Dry and Wet condition). be small for small changes of the abrasive flow rate.
The graphical representation of the wear test is observed Similar results of increase in wear with increase in flow
under the dry and wet conditions respectively in Fig. 4. rate are observed by Woldman et al. [12]. Scanning
According to wear test results it is observed that bare electron microscopic analysis of EN-31 steel after
samples performance is poor compare to hardfaced subjecting to abrasion wear with sandy sand under wet
specimens under both the condition (Dry and Wet). The conditions at 20N load and flow rate of 100g/min is
sever wear caused by the format grooves which become so shown in Fig. 6(a). The SEM morphology shows
deep under the dry and wet conditions by abrasive scratching as well as less deep grooves were taking place
particles. Both of the hardfaced samples reveal better simultaneously. The indentation of the sand particles is
wear resistance over the substrate due to high hardness not deep enough for heavy material removal. Scanning
and dendritric and interdendritic microstructure. Also electron microscopic analysis of EN-31 steel after
the hardfacing layer contains a large amount of carbides subjecting to abrasion wear with sandy sand under wet
and more alloying element as compared to base material. conditions at 20N load and flow rate of 200g/min is
But the HF1 slightly more wear resistance than HF2 shown in Fig. 6(b). The SEM morphology shows the
because of the presence of carbides of chromium and high surface of the specimen was characterized by wear scars
hardness value. Wear morphology of the bare, hardfaced and deep grooving. Their depth of grooves is high enough
specimen exposed to abrasive wear testing have been for huge material removal, as compared with the previous
shown in SEM. specimen. Scratch marks are formed to be deep and more
SEM analysis of the EN-31 steel after subjecting to prominent than the same test piece at 100g/min flow rate
abrasion wear with sandy sand under dry conditions at with the increase in flow rate, this attribute due to the
20N load and flow rate of 100g/min is shown in Fig. 5(a). number of particles sliding against the surface increase,
The SEM morphology shows wear scars as well as deep which results in higher abrasion rate
grooves were taking place simultaneously. The
indentation of the sand particles is deep enough as 3.5. Effect of sand particles
compared to hardfaced specimen under the same
Among the two testing conditions (dry and wet) all
conditions responsible for heavy material removal. The
samples (bare and hardfaced) has shows more weight loss
abrasive particles entrapped on wear surface due to lower
with sandy loam sand than sandy sand indicated in Fig.
hardness of the bare EN-31 as compared to hardfacings.
7. This is attributed due to more percentage of silt
The formation of craters has also been found in the
particles in sandy loam sand [13] and expose to gauge
specimen as shown in the Fig. 5(a). SEM analysis of the
ploughing during abrasion wear. The sever wear caused
EN-31 steel hardfaced with HF1 hardafcing after
by the formation grooves which become deep due to
subjecting to abrasion wear with sandy sand under dry
presence of silt in abrasive particles. Scanning electron
conditions at 20N load and flow rate of 100g/min is
microscopic analysis of EN-31 steel hardfaced with
shown in Fig. 5(b). The SEM morphology reveals only
Fe-carbide based electrode after subjecting to abrasion
wear marks however, does not show any deep crater or
wear with sandy sand under dry conditions at 20N load
pit formation. The abrasive particles are not able to
and flow rate of 100g/min is shown in Fig. 7(a). The
penetrate into the wear surface due high hardness value,
SEM morphology shows scratch marks as well as shallow
they just roll over the surface without causing any
grooves. The indentation of the sand particles is not deep
significant damage. This may be the reason for better
enough, which indicates lesser material removal as
wear behaviour of HF1 hardfacing compared to other
compared to sandy loam sand. Somewhere
tested specimens. SEM analysis of the EN-31 steel
microploughing wear mechanism is observed in the
hardfaced with HF2 hardafcing after subjecting to
specimen. SEM analysis of the EN-31 steel steel
abrasion wear with sandy sand under dry conditions at
International Journal of Surface Engineering & Materials Technology, Vol. 7, No. 1, January-June 2017, ISSN: 2249-7250 25
Singh, Chatha, and Garg Abrasive Wear Behavior of Hardfaced En-31 Steel

Figure 4: Cross section microstructure of (a) EN-31 steel (b) EN-31 Steel hardfaced with HF1 hardfacing (c) EN-31 steel hardfaced with HF2
hardfacing (Original magnification 100X).

Figure 5: SEM analysis of (a) EN-31 steel (b) hardfaced with HF1 (c) hardfaced with HF2 after subjecting to abrasion wear with sandy sand
under dry conditions at 20N load and flow rate of 100g/min.

Figure 6: EN 31 steel after subjecting to abrasion wear with sandy sand under wet condition at 20N rate of (a) 100gm/min (b) 200gm/min.

hardfaced with Fe-carbide based after subjecting to wheel. The depth of grooves is high enough for high wear
abrasion wear with sandy loam under dry conditions at rate than the same sample used under sandy sand.
20N load and flow rate of 100g/min is shown in Fig.
7(b). In this specimen the grooves are deeper, wider and 3.6. Effect of moisture content on wear
have more density per unit area (closer to each other). Among the two testing conditions (dry and wet) all
The dimension of lips adjacent to the grooves increased samples (bare and hardfaced) has shows more weight loss
and detachment occurred in the lips by abrasive particles during dry condition as shown in Fig. 8. Water tends to
as shown in Fig. 7(b). High density of microploughing lubricate the contact between the particles and the test
wear mechanism has been experienced by the sample, piece, especially with small and/or rounded particles and
which may be due to sliding and rolling action of the thus the wear rate is reduced. The lubrication has altered
abrasive particles in between the surface and rubber the motion of the particle from a primarily rolling action

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Singh, Chatha, and Garg Abrasive Wear Behavior of Hardfaced En-31 Steel

Figure 7: EN 31 steel hardfaced with Fe-carbide based after subjecting to abrasion wear with under dry conditions at 20N load and flow rate
of 100g/min with (a) Sandy sand (b) Sandy loam sand.

Figure 8: EN-31 steel after subjecting to abrasion wear with sandy sand at 20N load and flow rate of 100g/min under (a) Dry condition (b)
Wet condition.

in the dry environment to one of sliding in the wet scratches parallel to the direction of particle motion.
environment. The result shows that the water has
reduced the severity of damage caused by the abrasive
4. Conclusion
particles resulting in a smoother, less disrupted surface,
similar results have also been observed by In the present work abrasive wear behaviour of bare
Wirojanupatump and Shipway [14], 200 SEM analysis of (EN-31 steel) and hardfaced EN 31steel has been
EN-31 steel after subjecting to abrasion wear with sandy investigated under the wet and dry conditions at different
sand under dry conditions at 20N load and flow rate of flow rate and different sands. The following conclusions
100g/min is shown in Fig. 8(a). The SEM morphology were drawn.
shows both the grooving and wear scares were taking
place simultaneously with high density. Long continues 1. The average microhardness value of the substrate
grooves have more density per unit area, that indicates steel has been found to be less (119.6 Hv) than the
the more wear rate under the given testing conditions.. hardfaced steel. The average microhardness of HF1
Wear morphology shows a deeply indented and rough and HF2 hardfacing specimen is found to be 183.3
surface of the test piece following dry abrasion. SEM Hv and 177.1 Hv respectively.
analysis of EN-31 steel after subjecting to abrasion wear 2. As the hardfacing steel (HF1) has shown better
with sandy sand under wet conditions at 20N load and wear behavior than bare steel under both the wet
flow rate of 100g/min is shown in Fig. 8(b). The SEM and dry condition of testing. Therefore it will be
morphology shows both the grooving and wear scares actual significant to use the hardfaced plowshare in
were taking place simultaneously with low density than actual field environment, where the moisture
in dry condition. Long continues grooves have low content varies in the soil.
density per unit area, that indicates the less wear rate as 3. For bare as well as hardfaced steels, the abrasive wear
compare to dry condition. In the wet environment, there rate increases with increase in abrasive particle flow
is evidence of abrasive particle sliding across the surface rate.

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Singh, Chatha, and Garg Abrasive Wear Behavior of Hardfaced En-31 Steel

4. Under all testing conditions the wear rate of bare

and hardfacings steel has been found to be higher
for sandy loam than the sandy sand. This may be
due to hard and sharp edge particles present in the
sandy loam sand.

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