Ador Zedalloy Hardfacing Electrodes
Eight grades, 25 to 62 HRc · hardness, layers, sizes and amperage from Ador’s own datasheets · supplied from Secunderabad
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Choosing by hardness, not by name
Hardfacing grades are bought on the number the deposit reaches and how it gets there. Two figures decide almost every selection: how hard the deposit is and how many layers it takes to get there. A grade quoting 58 HRc in one layer and a grade quoting 56 HRc in three are not the same purchase — the first reaches working hardness immediately, the second needs the build-up.
Every figure below is Ador’s own published value, with the layer count stated alongside it, because a hardness number without the deposit conditions is not a specification. Where a grade work-hardens in service rather than as welded, both figures are shown.
| Grade | Deposit hardness | Diameter & current | Supply | Re-drying |
|---|---|---|---|---|
| Zedalloy 250 Moderate abrasion & impact | 25 HRc (255 BHN) 3 layer, as welded | 3.15 mm 100–140 A · 4.0 mm 140–180 A · 5.0 mm 180–220 A | AC (70 OCV) / DCEN | 110 °C for ½ hr |
| Zedalloy 350 Moderate abrasion & impact | 35 HRc (330 BHN) 3 layer, as welded | 3.15 mm 100–140 A · 4.0 mm 140–180 A · 5.0 mm 180–220 A | AC (70 V) / DCEN | 110 °C for ½ hr |
| Zedalloy 550 Moderate abrasion & impact | 56 HRc (580 BHN) 3 layer, as welded | 3.15 mm 100–130 A · 4.0 mm 140–180 A · 5.0 mm 180–220 A | AC (70 V) / DCEN | 110 °C for minimum ½ hr |
| Zedalloy 600 Moderate abrasion & impact | 58 HRc (600 BHN) 1 layer, as welded | 3.15 mm 100–140 A · 4.0 mm 140–180 A · 5.0 mm 180–220 A | AC (70 OCV) / DCEP | 110 °C for minimum ½ hr |
| Zedalloy 650 Severe abrasion, moderate impact | 57–62 HRc As welded | 3.15 mm 90–120 A · 4.0 mm 120–170 A · 5.0 mm 160–260 A | AC (70 V) / DCEP / DCEN | 100 °C for 1 hour if the electrodes are moist |
| Zedalloy 55P Abrasive & impact wear | 57–61 HRc As welded | 3.15 mm 110–150 A · 4.0 mm 140–190 A · 5.0 mm 190–260 A | AC (70 OCV) / DCEP | 250–300 °C for minimum 1 hour |
| Zedalloy 20Cr High impact, corrosion resistance | 16 HRc (200 BHN) as welded · 55 HRc (560 BHN) work hardened 3 layer | 3.15 mm 100–140 A · 4.0 mm 140–180 A · 5.0 mm 180–220 A | AC (70 OCV) / DCEP | 250–300 °C for minimum 1 hour |
| Zedalloy Bell Abrasion & corrosion, hot wear | 55 HRc (550 BHN) at room temperature · 52 HRc (515 BHN) at 500 °C 3 layer, as welded | 3.15 mm 90–110 A · 4.0 mm 110–180 A · 5.0 mm 160–220 A · 6.3 mm 210–280 A | AC (70 OCV) / DCEP | 250–300 °C for minimum 1 hour |
All eight are supplied in Ador’s standard 20 kg carton of four 5 kg packs, in 3.15, 4.0 and 5.0 mm × 450 mm (Zedalloy Bell also in 6.3 mm × 350 mm). Figures are Ador’s published values; confirm against the current datasheet for the batch you buy.
What each grade is for
Zedalloy 250
Rutile coated, air-hardenable and machinable. Good against rolling and sliding friction. Buffer layer of Tenalloy-16 recommended on hard base materials.
Zedalloy 350
RDSO approved. Machinable with carbide tools, high weld metal recovery. Kiln tyre supporting rollers, wobbler ends, cams, gear shafts, girth gears in cement and power plants.
Zedalloy 550
Non-machinable. Against high-stress abrasion and friction with moderate impact; resistant to spalling and cracking. Disintegrator hammers, excavator teeth, bulldozer blades, cane cutting knives.
Zedalloy 600
Rutile heavy coating, extremely hard non-machinable deposit, high hardness in a single layer. Suitable for high-carbon and high-sulphur steels.
Zedalloy 650
All positions except vertical-down. Air-hardening deposit, high hardness even in a single layer, multi-layer deposit without fissures or cracks. Hot and cold punching dies, crusher hammers, road graders, shears and croppers.
Zedalloy 55P
All positions except vertical-down. Air-hardening martensitic deposit, smooth arc with nil spatter. Also available vacuum packed.
Zedalloy 20Cr
Basic-coated work-hardenable electrode, typical 20% Cr semi-austenitic deposit, machinable and crack-free. Also used as a buffer layer before hardfacing. Conveyor rolls, truck chains, pulveriser plows, pump housings.
Zedalloy Bell
Basic type, crack-free in heavy build-up. No drop in hardness at 500 °C thanks to secondary hardening — the grade for hot wear where the others soften.
Two things worth getting right before you weld
The buffer layer
Ador recommend a buffer layer of Tenalloy-16 under Zedalloy 250, 350 and 550 on hard base materials. Zedalloy 20Cr is itself used as a buffer layer before hardfacing. Skipping the buffer on a hard or unknown base is the usual cause of a deposit that cracks off in service rather than wearing down.
Re-drying
The rutile grades (250, 350, 550, 600) re-dry at 110 °C for half an hour. The basic-coated grades (55P, 20Cr, Bell) need 250–300 °C for at least an hour — a different oven setting and a different holding time, and treating them alike is a common shop-floor error. Zedalloy 650 needs 100 °C for an hour only if the electrodes have picked up moisture.
Related
- Ador Fontech hardfacing and wear-resistant solutions — wear plates, flux-cored wires, ceramic-lined pipe
- Welding electrodes — the full Ador consumable range we stock
- Welding electrode selection guide
- Cement plants and mining and quarrying — where these grades go