November 10, 2025

Why Choose Hardfacing? Benefits and Industrial Applications Explained

By Jack Watson and Nolan Watson

For more than 70 years, HFW Industries has been a trusted leader in hardfacing industrial process equipment, restoring and protecting components exposed to extreme wear, heat, corrosion, and impact. Since our founding as Hard Face Welding & Machine Co., Inc., we have accumulated the experience, job records, and process knowledge needed to successfully perform even the most difficult hardfacing applications. We work across various critical industries including chemical processing, oil & gas, and power generation.

As a true one-source provider, HFW integrates hardfacing, precision machining, grinding/finishing, thermal spray coatings, assembly, and inspection under one roof. This ensures consistent quality, faster turnaround, and full accountability at every stage of the repair or manufacturing process.

What Are the Benefits of Hardfacing?

Hardfacing dramatically extends the service life of industrial components by adding a durable, metallurgically bonded overlay that resists abrasion, corrosion, heat, and impact. It allows worn parts to be restored to OEM specifications at a fraction of replacement cost, reducing downtime and total cost of ownership. 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 under one roof, HFW delivers repeatable, reliable hardfacing solutions built for demanding industrial environments.

Decades of Proven Hardfacing Experience

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, ensuring we consistently meet or exceed customer expectations.

HFW has hardfaced thousands of components used in:

Hardfacing Application Process

Every successful hardfacing 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 industrial hardfacing 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

Once the ideal process is identified, HFW selects or develops a qualified weld procedure to achieve the required performance.

Critical Weld Procedure Parameters


To ensure 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
    • Visual inspection

Only with well-controlled parameters and documented procedures can hardfacing be consistent, repeatable, and built for long-term performance.

Hardfacing 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 (GTAW) Welding
  • 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.

Hardfacing can be applied to:

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

One-Source Hardfacing, Machining & Thermal Spray Services

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 lead times, ensures consistent quality, and allows HFW to restore components to OEM specification. 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 1/3 the cost.

Partner With HFW for Reliable, Repeatable Hardfacing

Whether you're rebuilding worn equipment, adding selective wear protection to new components, or integrating thermal spray and machining with hardfacing, HFW delivers durable, engineered solutions backed by more than 70 years of experience.

Our team evaluates each application with precision, ensuring the right alloy, the right process, and the right procedure for your operating environment.

Need a Custom Hardfacing Solution?

Connect with our team for a customized solution to your toughest machinery challenge.

📞 Call us at (716) 875-3380
📧 Email: RFQ@hfwindustries.com

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Why Choose Hardfacing? Benefits and Industrial Applications Explained