Technical Bulletin     Standard Tungsten Carbide Cladding Formulas — Power Generation Download PDF here (720kb)    Engineered Formulas Conforma Clad has compiled over twenty years of scientific testing to develop three standard tungsten carbide cladding formulas that meet most of your severe wear protection needs. Our standard cladding formulas are designed to protect equipment from multiple modes of wear, including abrasion, erosion, corrosion or any combination of the three. Conforma Clad engineers evaluate individual components and their operating environments in order to recommend a standard cladding formula, or create a custom cladding to meet customer-specific requirements. Our unique infiltration brazing process combines the hardness of tungsten carbide with the corrosion-resistance of nickel chrome boron, to create a protective barrier with unmatched wear-resistant properties. With a metallurgical bond strength in excess of 70,000 psi, our cladding is extremely resilient to chipping, cracking and flaking.   Cladding Specifications Cladding Composition (Weight Percentage)   WC 200 WC 210 WC 219 Tungsten Carbide* 62% 55% 48% Nickel 30% 34% 39% Chromium 6% 7% 8% Other 2% 4% 5% Total carbide loading from other carbide formation 68% 66% 62% *Tungsten Carbide (WC) includes cobalt bonded WC. Cladding Properties   WC 200 WC 210 WC 219 Density (lb/in3) 0.44 0.42 0.40 Thermal Conductivity (BTU in/h•ft2•°F) 230 200 170 Metallurgical Bond Strength (psi) >70,000 >70,000 >70,000 Porosity <3% <3% <3% Rockwell Hardness (HRC)** 64-70 60-66 56-62 **Cladding is a composite of tungsten carbide particles dispersed in a nickel-based alloy matrix. The extremely hard carbide particles, with a Vickers Diamond Pyramid Hardness of about 2000 DPH50g [1865 DPH50g is equivalent to 80 Rockwell C Hardness (HRC)], are surrounded by a two-phase matrix (300-800 DPH50g, equivalent to 30-64 HRC). Because of the heterogeneous structure of the cladding, direct Rockwell hardness measurements are an average of the hard particles and matrix, and are not representative of the individual components of the composite. Cladding Photomicrograph Cladding Dense tungsten carbide loading with uniform carbide distribution - high wear resistance with predictable wear rates and continuous operation up to 1900°F No interconnected porosity - superior corrosion and impact resistance Bond Line True metallurgical bond (>70,000 psi) with high interparticle bond strength - provides unsurpassed strength and prevents chipping, fl aking and check cracking Diffusion Zone Minimal dilution - substrate retains uniform properties in diffusion zone Substrate Heat treatable - can be heat treated after cladding process to restore substrate’s mechanical properties Performance Data  EPRI field studies verify that 1/16" of Conforma Clad’s tungsten carbide cladding provides the same erosion protection as approximately 1" of chrome carbide weld overlay, or 3" of carbon steel. Black Beauty Coal Slag Erosion Test   Laboratory testing, following ASTM G73 standards, on low swirl coal spreaders determined Conforma Clad’s WC 219 provided the best erosion protection from fine grit black beauty coal slag. Babcock Power, CCV-DAZ Development Project Fly Ash Erosion Test   EPRI testing found that Conforma Clad’s WC 210 provides superior erosion protection for power boiler fan blades exposed to high-velocity bituminous coal fly ash. EPRI CS - 6068, Project 1649-4 Corrosion Test ASTM G31 testing shows Conforma Clad’s WC 210 provides superior corrosion resistance. Laboratory Testing, ASTM G31 Standards Hot Erosion Test EPRI testing at elevated temperatures confirms that Conforma Clad’s WC 200 protects boiler tube applications from erosive wear better than other accepted alternatives. EPRI Report 1008037 Cladding Properties  Properties Conforma Clad® Thermal Spray Weld Overlay Ceramic Tiles AR Plate Bond Strength Very High Very Low High Low N/A Complex Geometries Yes No Difficult Difficult Very Low Abrasion Resistance Very High Moderate High Very High Very Low Erosion Resistance Very High Low-Moderate Low Low Very Low Corrosion Resistance High Low Low Low Low Impact Resistance Moderate Low Moderate Very Low Low Oxide Level Low High Low Low Low Temperature Resistance High Moderate Low Very Low High Resists Multiple Modes of Wear Yes No Yes No Yes