Broco, Inc. PMA Division
Contact: Michael Heileman
8726 Production Ave. Ste. A
San Diego, CA 92121
U.S.
Phone: 858-271-1882
Fax: 858-271-8618
PMA Hardsurfacing Products
* VERSAlloy® Plus Nickel Alloys
* VersaAlloy Diamond Carbide
* Nickel Powder Metallurgy Preform
* Nickel Brazing Alloys
* VERSAClad
* Corrosion Resistant Alloys
* Wear-Resistant Alloys
* Data Sheet Specifications
* 30 years of experience in analyzing and solving a broad array of industrial wear problems.
* Carefully selected and processed alloys offer maximum performance under even the most rigorous conditions of abrasion, erosion, corrosion and high temperature.
* High quality VERSAlloy® nickel brazing and hardfacing materials in rod, wire, electrode and powder form.
* Rods as small as .031" diameter, as well as customized preforms, in nickel alloys to meet AMS and AWS Specifications.
* Diamond Carbide nickel hardfacing products and VERSAClad parts to provide maximum resistance to the most severe wear, abrasion, corrosion and high temperature.
Broco-Protective Metal Alloys (PMA) is uniquely positioned to provide complete, specialized expertise in the field of wear-resistance. PMA offers more than 30 years of experience in analyzing and solving a broad array of industrial wear problems and providing a solid background in the performance of many alloys under diverse conditions. Because wear exists wherever there is motion, nearly every industry encounters wear problems and billions of dollars are lost each year through unplanned downtime, repetitive replacement of parts, increased maintenance, lowered production efficiency, and lowered sales due to poor product reliability. PMA wear-resistant products have been instrumental in reducing these losses and increasing cost savings for companies in a number of diverse industries by extending parts life well beyond their traditional limits.
With a full range of nickel alloys and tungsten carbide products to work with Broco-PMA carefully selects and processes those alloys which offer maximum performance under even the most rigorous conditions of abrasion, erosion, corrosion and high temperature. Broco-PMA welding materials for overlay and surfacing are produced using the latest technology and manufacturing techniques. However hostile the environment or application, Broco can recommend and supply the most appropriate and cost-effective solution. The VERSAlloy® line of hardsurfacing alloys includes welding rods, powders and wear resistant parts. The advanced technology and remarkable versatility of our VERSAlloy® line of high performance alloys yields customized products to combat virtually all types of wear. Virtually any combination of levels of hardness, impact resistance, and abrasion resistance can be customized to meet your most stringent requirements, and can be produced in small quantities.
Broco-PMA handles each specialized order quickly and with expert personalized response to customer needs. PMA maintains a substantial inventory of "hard-to-locate" alloys that permit us to offer overnight service world-wide.
Broco-PMA Products:
PMA Hardsurfacing Products
VERSAlloy® and VERSAlloy® Plus Nickel Alloys
Highest Purity Sintered Powder Rods
VersaAlloy Diamond Carbide
The Ultimate Nickel Hardfacing with Tungsten Carbide for Extreme Wear
Nickel Powder Metallurgy Preforms and Brazing Alloys
PMA Hardsurfacing Products
VERSAlloy® and VERSAlloy® Plus Nickel Alloys
Highest Purity Sintered Powder Rods
Application Process Procedures
* Hard-surfacing, maintenance and repair welding
* Maximum resistance to corrosion, high temperature and extreme wear.
Nickel is tougher than iron and is harder and more durable. Hardfacing Alloys are available in longest lasting RC60, impact resistant RC40 and versatile RC50 and RC55 hardness. RC15, RC25 & RC30 buildup alloys restore parts to original dimensions, creating a base for harder alloys. VERSAlloy® nickel alloys wet into cast iron easily. Nickel is abrasion, corrosion, and high temp oxidation resistant. Cast, stainless or mild steel parts overlaid with nickel alloys last 5 to 10 times longer than untreated parts or parts coated with common hardfacing. Nickel is the ideal hardsurfacing material because it lasts longer than iron and is more cost efficient than cobalt.
Nickel is the best material for cast iron repair. Arc-welding cast iron has drawbacks. Arc stress results from the rapid heating and quenching occurring within the casting. Stress accumulates around carbides which have formed, ultimately leading to cracking.
VERSAlloy® is applied by oxy-fuel process. The nickel wets easily into the cast iron resulting in a dense, strong machinable weld. Try our VS15, VS25, or VS30 alloys.
Easier to apply.
Nickel rods have a lower melting point than iron. The best way to hardsurface with nickel utilizes the oxy-acetylene process. The base material is heated to a sweat, without going liquid. When the nickel rod is introduced to the flame it melts quickly and flows on easily. VERSAlloy® rods can be manipulated to tailor the coverage to the requirement- stringer beads to total cladding or anywhere in between. VERSAlloy® powders are applied using a flame spray torch resulting in a smooth, even coating.
Why is no dilution important
When a welding arc is struck, steel goes liquid, the base alloy mixing with the weld material. When that weld material is an iron based hardfacing, the addition of base material to the alloy "dilutes" it, diminishing its resistant qualities. This is one of the reasons iron hardfacing can't standup to the use and abuse nickel hardfacing can. No dilution of the torch applied nickel hardsurfacing makes it a superior coating.
Sintered rods = Highest purity.
Broco- Protective Metal Alloys' distinctive trademark trapezoidal rods are manufactured using the liquid phase sintering process. Nickel alloy powders are carefully brought up to temperatures where the powder particles bond together without completely melting. This produces a 100% pure alloy rod, while ensuring the base chemistries are not altered. The process also allows for the addition of carbides in a wide range of percentages and sizes, something no other product can do. Alloys can also be blended to achieve more favorable work characteristics. Our VERSAlloy® rods are never contaminated by fillers, binders or tubes.
VERSAlloy® Plus offers additional protection from 10% tungsten carbide.
VERSAlloy® Plus is our famous liquid phase sintered nickel alloy rod, enriched with 10% finely powdered macro-crystalline tungsten carbide for even better wear resistance. VERSAlloy® plus is ideal for those applications where heat, impact and/or corrosion are predominant factors yet extra wear protection is needed.
VERSAlloy® & VERSAlloy® Plus
Nickel Hardsurfacing Advantages and Aplications
* Parts last longer than original
* Improved equipment efficiency
* Lower operating & maintenance costs
* Corrosion & high temperature resistant
* Wets into cast iron
* High purity, no binders or fillers
* 100% deposition efficiency
* Easy to use
Applications:
Pumps, casings, liners, plungers, impellers, Valves, augers, screws, paddles, mill rollers, drill shaft banding, mold repair, cast iron buildup, cutting blades, shears, and piping.
Product Rockwell C
Nominal Chemistry Melt Temp.
VERSAlloy® 60
AWS A5.13
NiCr-C 57-61 C: 0.74
Cr: 14.0
Si: 4.55 B: 3.5
Fe: 4.5
Ni: Bal 1900
VERSAlloy® 50
AWS A5.13
NiCr-B 48-52 C: .67
Cr: 13.5
Si: 4.25 B: 3.25
Fe: 4.25
Ni: Bal 1950
VERSAlloy® 40
AWS A5.13
NiCr-A 38-42 C: .45
Cr :11.0
Si: 2.25 B: 2.5
Fe: 2.25
Ni: Bal 2000
VERSAlloy® 30 30-35 C: .10
Cr:
Si: 3.5 B: 1.9
Fe: 1.0
Ni: Bal 1975
VERSAlloy® 25 23-28 C: .10
Cr:
Si: 3.2 B: 1.6
Fe: 1.0
Ni: Bal 1975
VERSAlloy® 15 14-18 C: .10
Cr:
Si: 2.5 B: 1.4
Fe: 1.0
Ni: Bal 2000
Application Process Procedures
In all cases minimum dilution processes are recommended to obtain maximum wear resistance. Always follow generally accepted industrial safety procedures and practices. Always apply and adhere to ANSI/ASC Z49.1 "Safety in Welding and Cutting" standards or similar local prevailing standards when using this equipment.
RC60, RC50, & RC40 deposits are not machinable.
Oxy-Acetylene (OAW)- DO NOT MELT BASE METAL. Use a 3x reducing flame (carburizing) to preheat the base metal to a "sweat." Introduce VERSAlloy® rod tip to the flame. Nickel will flow freely. Manipulate to cover desired area.
TIG (GTAW). Use DC electrode negative (straight polarity) with largest size tungsten electrode available to minimize tungsten contamination of the weld puddle.
Flamespray (Puddle Torch)- DO NOT MELT BASE METAL. Use a 3x reducing flame (carburizing) to preheat the base metal to a "sweat." Depress hopper lever on torch to Introduce VERSAlloy® powder to the flame. Manipulate to cover desired area.
SMAW (Coated Electrodes. For faster deposition and field work, electrodes are preferred. They can be run either AC or DC. DC reverse polarity is recommended.
RECOMMENDED AMPERAGES
Size DC/RP
1/8" 3.175mm 80 - 100
5/32" 3.969mm 110-140
3/16" 4.762mm 140-170
1/4" 6.350mm 170-220
VersaAlloy Diamond Carbide
The Ultimate Nickel Hardfacing with Tungsten Carbide for Extreme Wear.
Application Process Procedures
* Diamond Carbide is the ultimate in wear protection in 40, 50, and 60 RC.
* Custom blends of tungsten and nickel for your specialized applications.
Diamond Carbide provides the highest degree of resistance to severely abrasive wear. The Nickel Matrix and Tungsten Carbide can be formulated for specific applications.
Why Nickel
Nickel is tougher than iron and is harder and more durable. Hardfacing Alloys are available in longest lasting RC60, impact resistant RC40 and versatile RC50 and RC55 hardness. Nickel is abrasion, corrosion, and high temp oxidation resistant and is the ideal hardsurfacing material. Cast, stainless or mild steel parts overlaid with nickel alloys last 5 to 10 times longer than untreated parts or parts coated with common hardfacing. Nickel is the ideal hardsurfacing material because it lasts longer than iron and is more cost efficient than cobalt.
Easier to apply.
Nickel rods have a lower melting point than iron. The best way to hardsurface with nickel utilizes the oxy-acetylene process. The base material is heated to a sweat, without going liquid. When the nickel rod is introduced to the flame it melts quickly and flows on easily. The rod can be manipulated to tailor the coverage to the requirement- stringer beads to total cladding or anywhere in between.
Why is no dilution important
When steel is welded it goes liquid, the base alloy mixing with the weld material. When that weld material is an iron based hardfacing, the addition of base material to the alloy "dilutes" it, diminishing its resistant qualities. This is one of the reasons iron hardfacing can't standup to the use and abuse nickel hardfacing can. No dilution of the torch applied nickel hardsurfacing makes it a superior coating.
The Tungsten Carbide edge.
Almost nothing stands up to extreme wear as well as tungsten carbide. Not only are parts cladded with tungsten carbide better protected, the right tungsten carbide enhances their performance. Chunk carbide will assist the cutting action in pulp mills or on rock bits. A more moderate sized cast pellet will trap dirt in earthmoving applications, making a dirt-to-dirt interface minimizing erosion. Fine particle tungsten carbide blended with Broco's VERSAlloy® nickel alloy matrix virtually won't wear out! Diamond Carbide is the ultimate in wear protection.
Custom Blends for Specialized Applications
* DC40F Grade
* DC50F Grade
* DC60F Grade
Applications
Diamond Carbide nickel-tungsten carbide hardsurfacing should be applied any time steel or iron parts are subjected to severe erosion or abrasion.
The RC 60 matrix with macrocrystalline carbide is particularly suited to:
* Pump linings
* Screws / worms / augers
* Pipe elbows
* Turbine blades
* Mixer blade edges and faces
* Crushers (VS50)
RC 40 nickel matrix with macrocrystalline carbide is ideal for:
* Cutting blades
* Recycling shears / blades
* Pulp mills
* Ag implements
* Bucket teeth and edges
* Bits and scrapers
Industry Applications:
* Aerospace
* Power Generation
* Mining/Minerals, Petroleum Refining
* Drilling
* Chemicals/Plastics
* Construction/Heavy Machinery
* Agricultural Machinery/Process Equipment
* Wood/Pulp
* Rolling Mills
* Concrete/Aggregate
* Recycling.
Product Abrasion Galling Impact Corrosion High Temp Characteristics
Diamond Carbide 60
Exceptional hardness up to 1200°F, low friction, excellent corrision resistance. Severe wear with low impact: cams, shafts, bushings, valve seats, cement pumps
Diamond Carbide 55
Similar to VS60 with better impact and less crack sensitivity for moderate impact, high corrosion & wear for food/chemical/petroleum processing, pumps, screws
Diamond Carbide 50
Medium hardness with non-cracking weld deposits for impact and severe abrasion: mining bits, agricultural implements, pulp knives, cutting bars
Diamond Carbide 40
High temperature, high impact with medium abrasion. For rock bits, impact hammers, dies, molds, valve slides
Application Process Procedures
In all cases minimum dilution processes are recommended to obtain maximum wear resistance.
Always follow generally accepted industrial safety procedures and practices. Always apply and adhere to ANSI/ASC Z49.1" Safety in Welding and Cutting" standards or similar locally prevailing standards when using this equipment.
Diamond Carbide deposit is not machinable.
Oxy-Acetylene (OAW)- DO NOT MELT BASE METAL. Use a 3x reducing flame (carburizing) to preheat the base metal to a "sweat." Introduce Diamond Carbide rod tip to the flame. Nickel will flow freely. Manipulate to cover desired area.
TIG (GTAW)- Use DC electrode negative (straight polarity) with largest size tungsten electrode available to minimize tungsten contamination of the weld puddle.
SMAW (Coated Electrodes. For faster deposition and field work, electrodes are preferred. They can be run either AC or DC. DC reverse polarity is recommended.
RECOMMENDED AMPERAGES
Size
DC/RP
1/8" 3.175mm 80 - 100
5/32" 3.969mm 110-140
3/16" 4.762mm 140-170
1/4" 6.350mm 170-220
Nickel Powder Metallurgy Preforms
Broco-Protective Metal Alloy's unique powder metallurgy process lends itself to the manufacture of Nickel braze alloys in a variety of forms. Due to the boron content, these braze alloys have low ductility and therefore cannot be formed by conventional metalworking procedures.
Broco-PMA produces preforms up to 6" diameter with cross sectional areas as small as .020" to AMS specifications 4775, 4776, 4777, 4778 and 4783.
Broco-PMA Nickel Alloy Preforms Advantages
For multiple and repetitive furnace brazed assemblies, Broco-PMA nickel alloy preforms offer the following advantages:
* Our powder metallurgy preforms vary less than 1% in weight, thus each joint will have exactly the proper amount of filler material to produce a consistently optimum brazement.
* Use of prealloyed powders produces a homogeneous alloy structure throughout the cross-sectional area, thereby ensuring complete melting at proper brazing temperatures.
* Our powder metallurgy preforms offer considerable cost savings over competitive methods of manufacture.
* No binders or contaminants are used in our process as in tape, cartridges or braze rope.
* Preforms offer significant labor and time savings in assembly as compared to powders or pastes.
* Unlike pastes, cartridges and braze rope, solid powder metallurgy preforms have an indefinite shelf life with proper storage.
* In a multiple joint assembly such as a heat exchanger proper count of preforms will ensure that all joints have been filled.
Nickel Brazing Alloys
Nickel brazing filler metals are widely specified for their exceptional heat and corrosion resistance. They are used primarily for brazing stainless steel, nickel alloys, as in aerospace and industrial applications. Available forms are powder, rod, wire (down to 0.031") and custom performs. PMA's unique manufacturing process - utilizing Super Solidus Liquid Phase Sintering - permits fabrication of customized shapes and forms to meet customers' requirements. Brazing performs are of a homogeneous alloy, proving the exact amount of filler material and piece count for optimum brazement control. Preforms offer an overall savings in time, labor and material.
VERSAClad
VERSACLAD parts offer an alternative to welded or flamesprayed overlays. A wide variety of compositions can be deposited on hard to weld metals to solve severe wear problems.
Corrosion Resistant Alloys
Speciality welding alloys, including Hastelloys, Stellites, Monels, Inconels, Titanium, and Magnesium are certified to military and commercial specifications and offered at competitive pricing.
Wear-Resistant Alloys
Broco-PMA recommends a part made completely of a specialty alloy when a relatively large area of a smaller part is subjected to wear. We produce a wide variety of such wear/corrosion parts using several casting techniques and powder metallurgy to achieve the most cost-effective solution to any problem.
DATA SHEET SPECIFICATIONS
ALLOY
Name Spec.
SPEC.*
AWS A5.8
AMS
Nominal
Composition
Melt Temp
°F
Brazing
Range
°F
solidus
liquidus
VERSAlloy® 75
BNi-1
AMS 4775
Cr 14.0
B 3.0
Si 4.50
Fe 4.50
C 0.70
Ni REM
1790
1900
1950-2200
VERSAlloy® 76
BNi-1a
AMS 4776
Cr 14.0
B 3.0
Si 4.50
Fe 4.50
C 0.06 max
Ni REM
1790
1970
1970-2200
VERSAlloy® 77
BNi-2
AMS 4777
Cr 7.0
B 3.10
Si 4.50
Fe 3.0
C 0.06 max
Ni REM
1780
1830
1850 - 2150
VERSAlloy® 78
BNi-3
AMS 4778
B 3.10
B 4.50
C 0.06 max
Fe 0.50 max
Ni REM
1800
1900
1850 - 2150
VERSAlloy® 79
BNi-4
AMS 4779
B 1.90
Si 3.50
Fe 1.5 max
C 0.06 max
Ni REM
-
1800
1950
1850 - 2150
VERSAlloy® 82
BNi-5
AMS 4782
Cr 19.0
SI 10.0
B 0.03 max
C 0.10 max
Ni REM
-
1975
2075
2100 - 2200
VERSAlloy® 83
BCo-1
AMS 4783
Cr 19.0
Ni 17.0
Si 8.0
W 4.0
Fe 1.0 max
B 0.80
C 0.40
Co REM
2050
2100
2100 - 2250
VERSAlloy® 1610
BNi-6
P 11.0
C 0.10 max
Ni REM
-
1610
1610
1700 - 2000
VERSAlloy® 1630
BNi-7
Cr 14.0
P 10.10
B 0.01 max
Si 0.10 max
Fe 0.20 max
C 0.08 max
Ni REM
1630
1630
1700 - 2000
VERSAlloy® 1700
N/A
AMS 4764
Cu 52.50
Mn 38.0
Ni 9.50
-
1615
1700
1750 - 2000
VERSAlloy® 1850
BNi-8
Si 7.0
C 0.10 max
Mn 22.5
Cu 4.5
Ni REM
1800
1850
1850 - 2000
* Also meets many aerospace industry specifications such as Pratt and Whitney, Garrett, Textron Lycoming, GE & others
