Hard Face Overlays for Industrial Equipment Rebuild

Hard face overlays help restore and protect industrial components exposed to wear, heat, corrosion, and impact. For more than 75 years, HFW Industries has used hardface welding and weld overlay repair to rebuild worn surfaces, add selective protection to new parts, and support demanding process equipment applications.

Since our founding as Hard Face Welding & Machine Co., Inc., we have accumulated the experience, job records, and process knowledge needed to support demanding hardfacing and weld overlay repair projects. We work across critical industries including chemical processing, oil & gas, and power generation.

As a one-source provider, HFW integrates hardfacing, precision machining, grinding/finishing, thermal spray coatings, assembly, and inspection in one facility.

Benefits of Hard Face Overlays for Industrial Components

Hard face overlays can extend the service life of industrial components by adding a durable, metallurgically bonded overlay that resists abrasion, corrosion, heat, and impact. They allow worn parts to be restored to specification when the base component is a good repair candidate. Hardfacing can also be applied selectively to new components to prevent premature wear in critical areas. With multiple welding processes, alloy options, and integrated machining and finishing in one facility, HFW delivers hardfacing solutions built for demanding industrial environments.

Hardfacing can be applied to:

• New parts for selective wear protection
• Worn components requiring dimensional restoration
• OEM or non-OEM equipment
• Heavy-duty components exposed to severe service conditions

Hardfacing Experience for Repeatable Weld Overlay Repair

Our extensive job record library, built over seven decades, and our established welding procedures enable us to repeat successful applications even years later. Every job is supported by modern welding equipment and controlled through our ISO 9001:2015 registered quality system, with inspection at each operation.

HFW has hardfaced thousands of components used in:

• Chemical and plastics processing
• Power Generation & Turbomachinery
• Oil & Gas
• Mining & Extraction
• Pulp & Paper
• OEM manufacturing and capital equipment

Weld Overlay Repair Application Process

Every successful weld overlay repair project begins with a detailed understanding of three critical factors:

• Base metal chemistry
• The selected or recommended overlay alloy
• Clear acceptance and inspection criteria

Because hard face overlay requirements vary widely, the process selection depends on several factors, including:

• Size and geometry of the part
• Required hardness and alloy properties
• Operating environment
• Budget and lead-time constraints
• Amount of restoration needed

Critical Weld Procedure Parameters

To support durability, repeatability, and metallurgical integrity, HFW's weld procedures specify:

• Preheat temperatures
• Interpass temperatures
• Post-weld cooling and heat treatments
• Required number of weld passes
• Filler metal size and feed rates
• Finishing methods and acceptance criteria
• Inspection requirements, including: liquid penetrant testing, ultrasonic inspection, X-ray inspection, and visual inspection

Hardface Welding Materials & Processes

HFW applies a wide range of nickel-, cobalt-, iron-based alloys, carbides, and specialty materials supplied in rod, wire, or powder form to suit each job.

Hardfacing processes include:

• Arc Welding
• TIG welding (GTAW)
• MIG (GMAW) Welding
• Oxy-Fuel Torch Welding
• Plasma Transferred Arc (PTA): ideal for high-performance carbide and cobalt-based overlays
• Sprayweld (Thermal Spray + Fusing)

Each method creates a metallurgical bond between the overlay and the base metal. Thermal spray, on the other hand, forms a mechanical bond. The metallurgical integrity offered by hardfacing is crucial for applications requiring high heat tolerance, structural strength, abrasion resistance, and impact durability.

One-Source Hardfacing, Machining & Thermal Spray

What sets HFW apart is our fully integrated process flow. Instead of coordinating multiple vendors for welding, machining, thermal spray, and finishing, customers rely on a single partner. This vertically integrated model reduces handoffs and keeps the work under one quality system. We offer one traveler, one quality system, and one point of accountability. In one instance, our one-source solution cut a customer's assembly time by 75% at one-third the cost.

Talk to HFW About Hard Face Overlay Repair

HFW can help evaluate the right hard face overlay path for the job.

To discuss your application, email RFQ@hfwindustries.com. Submit a quote request with drawings, photos, operating conditions, and timing so HFW can review the application and next steps. You can also call (716) 875-3380.

Additional Technical Resources for Precision Manufacturing Professionals

• What Is Hardfacing? Weld Overlay Explained

  A primer on hardfacing: what it is, how weld overlay works, and when it's the right solution.

• Preventing Hardface Delamination

  Root causes of hardface delamination and the preparation, preheat, and procedure controls HFW uses to prevent it.

• Thermal Spray Coatings Explained: HVOF and Tungsten Carbide

  A comprehensive overview of HVOF and thermal spray coating processes, materials, and industrial applications.

• Cutting Assembly Time by 75% at one-third the Cost

  Case study: consolidating machining, coating, and finishing at HFW cut a customer's assembly time by 75% at one-third the cost.

• Repair vs. Replace: When Remanufacturing Beats Buying New

  Framework for evaluating whether to repair or replace worn equipment, with cost and lifecycle considerations.

Frequently Asked Questions About Hard Face Overlays

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