Welding Technology Review – www.pspaw.pl  Vol. 91(5) 2019   11 

DOI: http://dx.doi.org/10.26628/wtr.v91i5.1030 
 

Article 

The influence of positioning deposited beads direction  
to resistance on grind wear plates’ abrasive wear 
Michał Szymura1,*, Maciej Różański2  

1 Silesian University of Technology, Poland; 
2 Łukasiewicz Research Network – Welding Institute, Poland 

Maciej Różański Ph.D. Eng. maciej.rozanski@is.gliwice.pl; 
* Correspondence: Michał Szymura M.Sc. Eng. michal.szymura@polsl.pl 
Received: 10.04.2019; Accepted: 07.05.2019 

Abstract: The article presents the results of the study of the significance of influence of positioning 
deposited beads towards direction of abrasive movement, to resistance on grind wear plates 
HARDPLATE 100S’ abrasive wear. The study on relevance of influence was conducted by using 
completely randomized design. The range of study has covered testing the metal-material abrasive wear 
resistance, macroscopic and microscopic metallographic examination and hardness tests. 

Keywords: wear plate; hardfacing; abrasion; chromium cast iron; coatings 
 

Introduction 
Existing wear processes limit the operational life of machine parts and equipment. In industry  

the most common type of wear is abrasive wear (abrasion). It is estimated that it can be responsible for over 
60% of costs resulting from tribological wear [1÷3].  

Welding technologies enable applying layers and coatings resistant to abrasion. For example, 
surfacing is used in the production of plates with wear-resistant padding weld (wear-resistant plates), 
which allow even a few-fold reduction in the wear intensity of machine elements [1,2,4÷13]. 

Commonly, these plates are manufactured by surfacing using wire with a powder core of a layer with 
specific properties on a structural steel substrate. With the use of additional material that provides the 
required structure, padding welds are made, which have a high resistance to wear occurring during 
operation, e.g. abrasion, erosion, abrasion at impact loads and corrosion. The most often padding welds of 
wear-resistant plates correspond to the composition of high-alloy chromium cast irons, hence they are 
mainly used to counter abrasion under conditions of intense metal-mineral friction. The wide use of wear-
resistant plates also results from the possibility of their forming through plastic processing (rolling, 
bending) and the possibility of assembly through separable (e.g. screw) and inseparable (e.g. welded) 
connections. In order to ensure adequate dimensional accuracy, objects made of plates with wear-resistant 
padding welds are shaped by abrasive machining, e.g. by grinding wheels (Fig. 1) [1,6,7,13]. 

 
Fig. 1. View of support plates (made from grind wear plates) guide systems in ring-ball mills [13] 

http://dx.doi.org/10.26628/wtr.v91i5.1030
mailto:maciej.rozanski@is.gliwice.pl
mailto:michal.szymura@polsl.pl


Welding Technology Review – www.pspaw.pl  Vol. 91(5) 2019   12 

In the technical documentation of the parts of equipment for which the use of plates with ground 
wear-resistant padding weld is foreseen, the designers determine the direction of beads laid on the 
surfaced layer or leave the manufacturer the freedom of choice. The qualitative data given in the literature 
boils down to recommendations regarding the direction of beads of padding welds' beads in relation to the 
direction of abrasive motion [12]. However, no literature information was found containing quantitative 
data on abrasion resistance of ground padding welds depending on the position of stitches in relation to 
the direction of displacement of abrasive elements. Therefore, an attempt was made to determine the 
influence of the direction of motion of abrasive particles in relation to the direction of the padding weld's 
beads placement on the abrasion resistance of ground wear-resistant plates.  

The paper presents the results of tests for resistance to abrasive wear of the metal-mineral type for 
different values of angles of setting the beads’ direction of plates with ground wear-resistant padding weld 
HARD-PLATE 100S 6+4 produced by Welding Alloys in relation to the flow direction of the abradant.  
The significance of the impact was determined by conducting studies using a randomized complete 
statistical program. The scope of the research also included macro and microscopic metallographic 
examinations as well as measurement of the hardness of the welded layer. 

Materials 
HARDPLATE 100S 6+4 wear-resistant plates are manufactured by automatic surfacing with powder 

self-shielding wire to ensure the alloy of high-alloy Fe15 chromium cast iron according to PN-EN 
14700:2014-06, string beads with a layer thickness of approx. 4.0 mm on a non-alloy steel substrate S235JR 
according to PN-EN 10025-2:2007 with a thickness of 6.0 mm. These panels are recommended for protecting 
surfaces exposed to intensive metal-mineral abrasion at moderate impact loads [13]. 

The course of research 

Abrasion resistance testing 
The research aimed at determining the significance of the impact of the direction of bead placement  

in relation to the abradant's movement direction on abrasion resistance of ground wear-resistant plates 
HARDPLATE 100S was carried out using a complete randomized static pr ogram designed to assess  
the significance of the influence of one input factor on the output factor [14]. The significance level of 
influence α = 0.05 was assumed. The following angle values were adopted between the direction of motion  
of the abrasive elements and the direction of surfacing of the beads: 0°, 30°, 45°, 60°, 90°. For each angle 
value, 6 abrasion resistance tests of the metal-mineral type were assumed. According to the assumptions 
and the concept of randomization, 30 sheets of HARDPLATE 100S 6 4 plates were marked with natural 
numbers from 1 to 30 based on their production date ‒ from the latest to the earliest produced. Then a 
sequence of random numbers was obtained using a computer random number generator [15]. Using the 
generated sequence of numbers, the wear-resistant plates were randomly assigned to the appropriate 
values of the tested factor. The measurement scheme of a static randomized complete program taking into 
account the assumptions and assignment is presented in figure 2 [14]. The individual 75 x 25 mm samples 
were cut from the individual wear-resistant plates to ensure that the angle between the longer side of the 
sample and the direction of the bead placement was 0°, 30°, 45°, 60° or 90° (Fig. 3). The location of cracks in 
the surfaced layer of the samples was accidental. The cut samples were subjected to circumferential disk 
grinding. In the grinding process, the direction of the feed rate of the tangential table was parallel to the 
direction of bead placement.  

 
Fig. 2. Scheme of measurements of completely randomized design; 1 – angle between direction of abrasive movement 
and positioning of deposited beads 



Welding Technology Review – www.pspaw.pl  Vol. 91(5) 2019   13 

 
Fig. 3. Positioning of deposited beads of grinding wear plates samples towards direction of abrasive movement;  
1 – direction of abrasive movement, 2 – positioning of deposited beads, 3 – grinding wear plates samples 

Testing of abrasion resistance of the metal-mineral abrasion of wear-resistant plates was carried out on 
the basis of ASTM G 65, procedure A. During the test, the abrasive flow rate was 302 g/min. The samples 
were loaded with a constant force of 130 N. The friction wheel rotated at 200 rpm and the frictional path 
was 4309 m. Fire-dried quartz sand with spherical grain and granulation of 100÷300 μm was used as the 
abrasive sand. In order to determine the resistance to abrasive wear of padding welds, the loss of mass and 
density of the padding welds were measured. Samples before and after the study were weighed on 
laboratory scales with an accuracy of 0.0001 g. The average density of the wear-resistant plate used in the 
study was determined using a laboratory scale, based on three measurements of the density of the surfaced 
layer of one sample, weighed in air and liquid. The volume loss was determined using the mass loss values 
of the sample and the average value of the measured padding weld's density in accordance with formula 
(1). The results obtained are shown in table I. 

Uo =
Um
𝜌

∙ 1000     (1) 

where: 
Uo – volume loss, mm3; 
Um – mass loss, g; 
ρ – density, g/cm3. 

Table I. Results of the metal-material abrasive wear resistance test of grinding wear plates samples 
The angle between 

the direction of 
movement of 

abrasive particles 
and the direction 

of beads 
placement, ° 

Loss of the padding weld's volume, mm3* 
(loss of the padding weld's mass, g) 

1 2 3 4 5 6 
Average  

for individual   
levels 

0 
19.6682 
(0.1432) 

20.6571 
(0.1504) 

18,2947 
(0,1332) 

22,0305 
(0,1604) 

20,7669 
(0,1512) 

19,2561 
(0,1402) 

20,1123 
(0,1464) 

30 
20.8906 
(0.1521) 

22.8409 
(0.1663) 

19,5583 
(0,1424) 

21,4125 
(0,1559) 

20,3137 
(0,1479) 

23,2941 
(0,1696) 

21,3850 
(0,1557) 

45 
20.0527 
(0.1460) 

20.7532 
(0.1511) 

20,3824 
(0,1484) 

18,3222 
(0,1334) 

22,0168 
(0,1603) 

20,2176 
(0,1472) 

20,2908 
(0,1477) 

60 
20.7257 
(0.1509) 

20.7669 
(0.1512) 

20,0390 
(0,1459) 

22,5250 
(0,1640) 

19,0776 
(0,1389) 

20,6296 
(0,1502) 

20,6273 
(0,1502) 

90 
22.1542 
(0.1613) 

20.1764 
(0.1469) 

22,7722 
(0,1658) 

19,8193 
(0,1443) 

22,4975 
(0,1638) 

19,3660 
(0,1410) 

21,1309 
(0,1539) 

 For all results 
20.7093 
(0.1508) 

* loss of the padding weld's volume was determined according to the formula (1).  
Measured density of the padding weld of wear-resistant plate HARDPLATE 100S 6+4 is 7,2808 g/cm3 

According to the implementation scheme of the randomized complete statistical program, an analysis 
table of variance was created (Table II) 



Welding Technology Review – www.pspaw.pl  Vol. 91(5) 2019   14 

Table II. Analysis of variance table 

Name 
Sum of squares 

S 
Number of degrees 

of freedom f 
Average square 

s2 
Value  

of the test F 

Between 
systems 

𝑆𝑀𝑈 =  ∑ 𝑟𝑖
𝐾

𝑖=1

𝑦𝑖
2 − 𝑁𝑦2 = 7.03599 𝑓𝑀𝑈 = 𝐾 − 1 = 4 𝑠𝑀𝑈2 =

𝑆𝑀𝑈
𝐾 − 1

= 1.7590 
𝐹 =

𝑆𝑀𝑈2

𝑆𝑊𝑈
2

= 0.9993 

Inside  
the system 

𝑆𝑊𝑈 =  ∑ ∑ 𝑦𝑖𝑗
2

𝑟𝑖

𝑗 =1

𝐾

𝑖=1

− ∑ 𝑟𝑖

𝑟𝑖

𝑖=1

𝑦𝑖
2

= 44.00543 

𝑓𝑊𝑈 = 𝑁 − 𝐾 = 25 𝑠𝑊𝑈2 =
𝑆𝑊𝑈

𝑁 − 𝐾
= 1.7602 – 

Rest 𝑆𝑅 = ∑ ∑ 𝑦𝑖𝑗
2

𝑟𝑖

𝑗=1

𝐾

𝑖=1

−  𝑁𝑦2 =  51.04142 𝑓𝑅 = 𝑁 − 1 = 29 – – 

where: 
ri – the number of measurements of the input factor at a given level; N – total number of measurements of the input factor; 
�̅�

𝑖
 – average of measurement results; y ̅ – average of results from all measurements; 

yij – the value of the j-th resultative factor at the i level; K – number of variability levels of the tested factor 

Hardness measurements 
Measurements of hardness of layers of surfaced samples from ground wear-resistant plates were 

carried out on the surface of the padding weld's face using the Rockwell method (Fig. 4a) and for 2 samples  
on the cross-sectional area of the plate in the area of the overlap of the padding weld beads, heat affected 
zone and basic material using the Vickers method (Fig. 4b). The results of hardness measurements obtained 
are presented in table III, IV and V. 

  
(a) (b) 

Fig. 4. Hardness tests points distribution: a) on the face of overlay weld of grind wear plates; 1 – hardness test points, 
2 – grinding hardfacing deposit, 3 – base material, b) on the surface of grinding wear plates’ cross section; 1 – 
hardness test points, 2 – grinding hardfacing deposit, 3 – heat affected zone, 4 – base material 

Metallographic examinations 
In order to determine the quality of the surfaced layer, micro- and macroscopic metallographic examinations were 
performed. Metallographic examination of the sample with the number 19, whose angle between the longer side of 
the sample and the direction of beads placement is 0°, was carried out on transverse metallographic specimen using a 
light microscope. The results of macroscopic metallographic examinations are presented in figure 5a, and 
metallographic microscopic findings in figure 5b. 

  
(a) (b) 

Fig. 5. a) The macrostructure of grinding wear plate HARDPLATE 100S’ 6+4; b) and microstructure of hardfacing 
deposit of this plate 



Welding Technology Review – www.pspaw.pl  Vol. 91(5) 2019   15 

Table III. Results of HRC hardness measurements on the face of hardfacing deposit samples of grinding wear plates 

Sample 
number 

Angle between  
the longer side of the 

sample and the direction 
of beads placement, ° 

Hardness measurement point * Average value 
of the 

hardness of 
the sample, 

HRC 

1 2 3 4 5 

19 0 59.5 61.0 62.5 61.5 59.5 60.8 
10 0 59.0 60.0 62.5 61.0 60.5 60.6 
24 0 60.5 61.0 61.5 61.5 59.5 60.8 
08 0 59.5 60.0 60.5 61.0 61.0 60.4 
15 0 58.5 59.5 61.0 60.0 61.0 60.0 
27 0 62.5 62.5 60.5 59.5 60.0 61.0 
26 30 58.5 60.0 60.5 60.5 60.0 59.9 
14 30 60.5 60.0 61.5 60.5 61.0 60.7 
09 30 60.5 59.0 62.0 61.0 61.0 60.7 
02 30 59.5 61.5 60.5 60.0 60.5 60.4 
05 30 59.5 61.0 62.5 62.0 60.5 61.1 
28 30 59.5 60.0 60.5 62.0 61.0 60.6 
07 45 61.5 62.0 59.0 60.5 60.0 60.6 
25 45 60.5 61.5 61.0 62.0 60.5 61.1 
11 45 60.0 59.0 60.5 61.0 60.5 60.2 
06 45 60.5 59.5 61.0 61.0 58.5 60.1 
16 45 60.5 60.5 61.0 60.5 60.0 60.5 
29 45 60.5 61.0 60.5 60.0 59.0 60.2 
04 60 59.0 61.5 60.5 62.0 60.5 60.7 
03 60 61.0 62.0 60.0 60.0 59.5 60.5 
30 60 60.5 61.0 62.0 60.5 59.5 60.7 
21 60 60.0 58.5 60.5 60.5 60.0 59.9 
20 60 61.5 61.5 59.5 60.0 59.5 60.4 
17 60 59.5 60.0 61.0 60.0 61.0 60.3 
22 90 58.5 59.0 59.5 61.0 60.5 59.7 
01 90 62.0 60.5 60.0 61.0 59.0 60.5 
12 90 60.0 60.5 60.5 60.5 59.0 60.1 
13 90 59.5 61.5 62.0 60.0 60.0 60.6 
23 90 61.0 61.5 60.0 58.5 59.9 60.2 
18 90 60.0 62.0 62.0 59.5 60.0 60.7 

* marking of measurement points in accordance with figure 4a 

Table IV. Results of HV30 hardness measurements on cross section of hardfacing deposit samples of grinding wear 
plates 

Sample 
number 

Angle between the longer side 
of the sample and the 

direction of beads placement, ° 

Hardness measurement point * 

1 2 3 4 5 6 7 8 9 10 

19 0 804 711 761 814 754 825 709 729 791 803 

10 0 747 746 703 784 697 728 688 747 759 812 

* marking of measurement points in accordance with figure 4b 

Table V. Results of HV10 hardness measurements on cross section of heat affected zone and base material samples  
of grinding wear plates 

Sample 
number 

Angle between the longer side 
of the sample and the direction 

of beads placement, ° 

Hardness measurement point * 

11 12 13 14 15 16 

19 0 174 185 167 150 163 152 

10 0 177 170 161 148 154 141 

* marking of measurement points in accordance with figure 4b 



Welding Technology Review – www.pspaw.pl  Vol. 91(5) 2019   16 

Analysis of research results 
The conducted tests of abrasion resistance of ground wear-resistant plates HARDPLATE 100S showed 

that regardless of the direction of bead placement in relation to the direction of movement of abradant, the 
surfaced layer is characterized by high resistance to abrasion. The average loss of padding weld's volu- 
me determined based on ASTM G 65 for particular values of bead angles is in the range of 20.1123÷ 
÷21.3850 mm3. The significance of the impact study was conducted using a randomized complete statistical 
program. The value of the F test calculated on the basis of statistical analysis of test results (Table II) is less 
than the critical value F0.05; 4; F Fischer-Snedecor F test [14]. It authorizes us to state that for the adopted 
level of significance and the calculated number of degrees of freedom, the direction of bead placement  
in relation to the direction of movement of abrasive particles does not significantly affect the abrasion 
resistance of the metal-mineral type of plates with ground wear-resistant padding weld. 

The hardness measurements carried out on the face of the padding weld of ground wear-resistant 
plates show high hardness of the surfaced layers and high repeatability of results irrespective of the 
direction of bead placement with respect to the longer side of the sample. The average hardness values of 
individual samples are in the range of 59.7÷61.1 HRC, while the gap is 4.0 HRC. There was no deterioration  
of the padding weld's hardness in the bead joints zone. The hardness measured on the cross-sectional area 
of the padding weld is within 688÷825 HV30, and in the area of the beads' overlap 703÷761 HV30. The heat 
affected zone has a hardness of 161÷185 HV10, while the base material 141÷163 HV10. In both cases,  
the measured hardness does not exceed the maximum permissible hardness of 380 HV10 according to PN- 
-EN ISO 15614-7:2016-12 for steel from material group 1. 

The metallographic tests carried out did not indicate the occurrence of welding defects in the surface 
layer of the plate with wear-resistant padding weld. The surfaced layer is properly connected to the base 
material and the penetration has a regular circular shape. On the basis of microscopic examination, it can be 
concluded that the padding weld of the wear-resistant plate probably has a structure composed of large 
chromium carbides in the austenitic matrix. 

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terms and conditions of the Creative Commons Attribution (CC BY) license 
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