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Hardfacing is a metalworking process where harder or tougher material is applied to a base metal. It is Hardfacing welded to the base material, and generally takes the form of specialized electrodes for arc welding or filler rod for oxyacetylene and TIG welding. Powder metal alloys are used in (PTA) also called Powder plasma welding system and Thermal spray processes like HVOF, Plasma spray, Spray and Fuse, etc.


Hardfacing may be applied to a new part during production to increase its wear resistance, or it may be used to restore a worn-down surface. Hardfacing by arc welding is a surfacing operation to extend the service life of industrial components, pre-emptively on new components, or as part of a maintenance program.[1] The result of significant savings in machine down time and production costs has meant that this process has been adopted across many industries such as Steel, Cement, Mining, Petrochemical, Power, Sugar cane and Food. According to the results of an experimental study, the SMAW (Shielded Metal Arc Welding) and the GMAW (Gas Metal Arc Welding) hardfacing processes were effective in reducing the wear on the mouldboard ploughshare. With the SMAW and GMAW hardfacing processes, the life span of the ploughshare was increased approximately 2 times [1].[2]

Extensive work in research has resulted in the development of a wide range of alloys and welding procedures. The optimum alloy selection is made considering the component service conditions and feedback of the service performance.

For each industrial application and wear phenomena, there is a welding electrode to provide wear resistance.

Hardfacing can be deposited by various welding methods:

  • Shielded Metal Arc Welding (SMAW)
  • Gas Metal Arc Welding (GMAW), including both gas-shielded and open arc welding
  • Oxyfuel Welding (OFW)
  • Submerged Arc Welding (SAW)
  • Electroslag Welding (ESW)
  • Plasma Transferred Arc Welding (PTAW), also called Powder Plasma welding system
  • Thermal spraying
  • Cold polymer compounds
  • Laser Cladding

Commonly applied materials include cobalt-based alloys (such as stellite), nickel-based alloys, chromium carbide alloys and NOREM.
Hardfacing is sometimes followed by hot stamping to refinish the part
or add color or instructional information to the part. Foils or films
can be used for a metallic look or other protection.[3]


Refer it this web site for more information. (see below)


For more information on hardfacing products, please review these PDF.

Mining KSTS Presentation English
Kestra USA 11
Kestra Flux Cored Wire Catalog-MSC
Kestra Electrode catalog English-MSC
Cement Kestra Presentation MSC

About us

Metal Spray Coating is a company created to serve the North American, Central American & South American markets and provide them with Thermal Spray non-ferrous wires for corrosion protection and ferrous wires manufactured with the latest technology. Our technology includes anodic protection that seals and protects surfaces from corrosive elements.
Engineering applications that undergo surface spray welding and that can be used in conjunction with sealers and coatings for added lasting protection from wear & abrasion. We have different machines for every need and a range of thermal spray metallizing wires and soldering.
Our company is located in the state of Florida USA to serve the US market and for strategic logistics reasons to service the South American Market; we can deliver by sea freight or airfreight to South America and therefore offer a faster delivery and lower transportation costs.
Our Mission is to advise and recommend to our customers the best equipment and wires to fit their needs and obtain the best result possible in their thermal spray applications.


  • Corrosion Resistance
  • Industrial Hardfacing
  • Iron Base Hardfacing Alloys
  • Copper Base Alloys
  • Iron Base Alloys
  • Nickel Base Alloys
  • Thermal Spray Powders


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