A composite stellite alloy hardfacing with improved laser cladding behavior and wear resistance

To solve the existing wear and corrosion problems in power generation industry, this research investigates the wear and corrosion behavior of Stellite alloys in NaOH solution, which simulates the amine media in the feedwater service of power generation plants. The Stellite alloys under this study include Stellite 6 and a composite Stellite alloy. The composite Stellite alloy hardfacing, which consists of 70% Stellite 3 and 30% Stellite 21, is created via laser cladding for control valve seat sealing surfaces, aiming at enhancing hardness and wear resistance, compared with Stellite 6 hardfacing, and improving cracking in laser cladding process, compared with Stellite 3. The composite Stellite alloy hardfacing is made on 316 stainless steel substrate and it does not show any cracking. The microstructure of the hardfacing is analyzed using SEM, EDS and XRD. The hardness, dry sliding wear resistance and cavitation-erosion resistance in NaOH solution are evaluated. Stellite 6 hardfacing is prepared with the same laser process parameters and is also analyzed and tested under the same conditions with the composite Stellite alloy hardfacing for comparison. The experimental results and real industrial test demonstrate superior performance of the composite Stellite alloy hardfacing to Stellite 6 hardfacing for control valve seat sealing application.