Which Welding Rod for Hard Surfacing and Buildup
Top pick: Chromium Carbide Hardfacing Rod. 3 rods compared with settings for this application.
Safety-critical application. Hard surfacing rods produce higher fume levels than standard electrodes. Some hardfacing alloys contain hexavalent chromium. Work outdoors or use local exhaust ventilation.
Hard surfacing deposits a wear-resistant alloy on top of a softer base metal to extend the service life of parts that wear out. Bucket teeth, tillage points, crusher jaws, and conveyor screws are rebuilt daily with hardfacing rods rather than replaced. The correct rod depends on the type of wear: abrasion, impact, or a combination.
Best Rods for Hard Surfacing
Chromium Carbide Hardfacing Rod
Chromium carbide overlay for severe abrasion. Deposits a hard, wear-resistant surface (58-65 HRC) on carbon steel. Use for bucket teeth, tillage points, grader blades.
Manganese Steel Hardfacing Rod
Austenitic manganese steel overlay for impact wear. Work-hardens under impact. Use for crusher jaws, hammers, railroad crossings.
E7018
Buildup rod before hardfacing. Restores worn parts to dimension before applying hardfacing overlay. Not a hardfacing rod itself.
Quick Amperage Reference for Hard Surfacing
| Electrode | Polarity | Common Size | Amps | Full Chart |
|---|---|---|---|---|
| E7018 | DCEP / AC | 1/8" | 90-160A | E7018 chart |
Hard Surfacing Technique
Build up first, then overlay. If the part is worn below its original dimension, deposit E7018 buildup passes first, then apply 2-3 passes of hardfacing on top.
Stringer beads only. Do not weave hardfacing rods. Stringer beads minimize dilution from the base metal.
Checking cracks are normal. Chromium carbide overlays develop fine surface cracks as they cool. These are stress-relief cracks and do not affect wear performance.
Which Rod for Your Situation
Equipment You Need
Most hardfacing rods run on standard DC stick welders at 150-250A. No special equipment needed beyond standard stick setup and fume extraction.
Mistakes to Avoid With Hard Surfacing
Applying too many hardfacing passes. More than 3 passes causes the overlay to spall. Two passes is standard.
Overheating Hadfield manganese steel. Austenitic manganese must be welded cold with no preheat. Keep interpass temperature below 500F. Exceeding 500F causes carbide precipitation making it brittle. Work in short stitch passes (2-3 inches max) and let the piece cool between passes.
Using chromium carbide on impact applications. Chromium carbide is hard but brittle. It cracks under impact. Use manganese for impact wear.
What Goes Wrong
A quarry applied 5 passes of chromium carbide on crusher jaw plates. The thick overlay spalled off in sheets within two weeks. Rebuilt correctly with 2 passes, the plates lasted the expected 3 months.
Hard Surfacing: Common Questions
What welding rod for hard surfacing?
Chromium carbide for abrasion resistance (bucket teeth, tillage blades). Manganese steel for impact resistance (crusher jaws, hammers). Match the rod to the wear type. For buildup passes before hardfacing, see the E7018 specifications for settings.
Can you hard surface with E7018?
No. E7018 is a mild steel electrode at about 20 HRC with no wear resistance. Use it only as a buildup rod to restore dimensions, then apply actual hardfacing rod (58-65 HRC) on top.
How many passes of hard surfacing?
Two passes is standard. Three maximum. More than three builds thermal stress that causes the overlay to spall off in sheets.
As an Amazon Associate, GageRef earns from qualifying purchases. Electrode spec pages linked above may contain affiliate links.
Reference data only. Verify all settings against manufacturer documentation and the applicable welding code before use. Amperage ranges are starting points that vary by position, fit-up, and material. Welding involves serious injury risks including burns, electric shock, fume exposure, and fire. This site does not replace proper training, certification, or employer safety procedures. See full terms of use.