Tungsten itself is extremely hard (around HRC 90). One of the main issues with existing tungsten hardfacing companies is the reliance on mild steel matrix weld. Even though there is a chemical reaction occurring between the Cobalt and in the weld process that slightly increases the matrix hardness, it is insufficient to stop abrasive material wearing away the weld between tungsten chips. This leads to increased wear.

The other problem is gravity fed systems drop tungsten on the surface of the weld. The product looks similar to other injected processes but will wear quickly once the top layer of tungsten has worn away.

Other problems often cited by people that have used other suppliers of tungsten hardfacing are the appearance of craze cracking and porosity in the weld. This along with poor bonding between the weld and the parent metal can result in large sections falling off. We see these phenomena with people using tungsten coating machines that were originally designed solely for tungsten coating in agricultural applications. Often these machines lack the ability to achieve adequate parent metal penetration. Many of these machines rely on low level tungsten delivery into a 0.9mm mild steel welding wire.

ATC Group currently supplies overlay parts to six business owners who own tungsten overlay machines. One of our customers owns a machine he paid $65,000 for as part of a franchise. None of these six use their machines at all. Compared to paying approximately $50 per kilo for tungsten grit, our price and part longevity means it is more economical to have their parts supplied and overlayed by ATC Group.

If you have had a bad experience with tungsten overlay, or if you are paying a lot for average results – contact us and we will give you a free trial of our process. We know ATC overlay will work for you!