Welding & Hardfacing Consumables

With over 100 years of proven performance, Kennametal Stellite™ is known as the worldwide hardfacing solution provider for wear, heat and corrosion applications.

Kennametal Stellite’s thermal spray and hardfacing consumables are manufactured as cast rods, wire, powder and electrodes from our portfolio of over 300 unique alloys. Each of these alloys is backed by performance across major industries including aerospace, oil & gas, automotive, e-mobility, power generation, steel, timber, glass, dental and petrochemical processing.

Thermal Spray & Hardfacing Powder

Kennametal Stellite is the premier manufacturer of high-alloyed metal powders for a wide variety of thermal spray and hardfacing applications. Our powder production capabilities include gas atomization, macrocrystalline carbide production and conventional carburized carbide production.

Powders are available in a wide variety of mesh sizes & chemistries and have optimized morphology, flowability and density based on the application technique: 

• PTA: This highly efficient method of hardfacing is used to produce overlays in a wide range of hardnesses and compositions. 
• Laser Welding: A focused laser beam heats the workpiece as powder is introduced, offering higher hardnesses and finer microstructures.
• Spray & Fuse: Spray & Fuse process is used for relatively thin layers, usually on the surface of small cylindrical objects such as pump shafts or pistons.
• HVOF: Powder particles are heated in a gas stream and transferred by a supersonic energy stream to the surface of the workpiece.
• Plasma Spray: A contained plasma stream transfers softened metals to the workpiece. Ideal for spraying high melting point metals and oxides.
• Powder Welding: Powder welding is the ideal process for the deposition of smooth, thin, well-bonded layers on flat surfaces on a wide range of substrates. 

Stellite Cored Welding Wire

Claddings made from Kennametal’s Stellite cored welding wires resist corrosion, galling, erosion and general wear while retaining a high degree of hardness at elevated temperatures. Applications for these claddings include sealing faces on fluid control valves, mixer rotors used in the rubber industry, plastic & food extrusion screws, hot working tools and closed dies.

The metal cored wire is available in sizes ranging from 0.45”-.125” and is typically used with MIG or SAW welding process.

• MIG (GMAW): In Metal Inert Gas (MIG) welding, also known as Gas Metal Arc Welding (GMAW) the wire is fed continuously into the arc, where it is melted and transferred to the workpiece. The MIG process is very flexible and is suitable for a wide range of applications.
• SAW: In Submerged Arc Welding (SAW) a fluxing powder flows around the wire which forms a protective gaseous shield around the weld Arc and the top of the weld pool.

Welding Rods & Electrodes

Kennametal Stellite produces one of the industry's most extensive portfolios of hardfacing weld rods and electrodes. These products produce claddings for extreme applications including valves & pumps for oil & gas, cutting tools & saw blades for timber, crusher jaws & dredge buckets for mining and turbine blades for power generation.

All of Kennametal Stellite’s rods and electrodes are cast using a multi-strand continuous casting process and are available in a wide range of diameters, finishes and lengths.

• TIG (GTAW): TIG (Tungsten Inert Gas), also known as Gas Tungsten Arc Welding (GTAW), the electrode, the arc, the rod and the weld-pool are protected from the atmosphere with an inert shielding gas. The advantages of TIG include simple manual operation and good control of the welding arc. 
• Oxy-Acetylene: Oxyacetylene welding (aka gas welding) is a process that uses a combination of oxygen and acetylene gases to create a high-temperature flame to melt a small amount of the base metal and a hardfacing rod, allowing a cladding to form.
• MMA (SMAW): MMA welding (aka Manual Metal Arc welding or Shielded Metal Arc Welding (SMAW)), is a process that uses a electrode coated in flux to create a cladding. The flux on the electrode forms a protective gas shield, preventing oxidation or contamination from the surrounding air.