Recycling of submerged arc welding slag into a hardfacing flux and its characterization

Submerged arc welding (SAW) slag is an industrial waste, generated in large quantities. Its disposal leads to the wastage of non-renewable resources and contributes to environmental degradation. Developing a hardfacing flux from waste-submerged arc welding slag marks a significant advancement in sustainability and industrial efficiency. By repurposing this byproduct, the approach not only tackles the issue of waste management but also conserves non-renewable resources and reduces costs. The resulting hardfacing layers were rigorously tested for chemical, mechanical, and metallurgical properties. The chemical composition of these hardfacings met the DIN 8555 specifications, and they successfully passed the side bend test, demonstrating a robust bond between the hardfaced layer and the base metal. Performance evaluations showed a 63.22% improvement in wear resistance, with a reduced coefficient of friction (0.251 compared to 0.293 for the base material), and a 220% increase in hardness. The hardfaced layers exhibited a defect-free, fine-grained microstructure. With recycling costs at merely 33% of virgin flux, this technology offers a cost-effective and environmentally sustainable alternative for hardfacing applications.