Solutions Flash

Improved Surface Protection for Marine and

Non-Marine Hydraulic Rods

SF-0030.0 – October 2020

SF-0030.0 – Surface Solutions for Marine and Non-Marine Hydraulic Rods

© 2020 Oerlikon Metco 1
Today’s Situation
Hydraulic cylinder rods are well-known in many industries as Hydraulic cylinders used in mining application such as subter-
an effective method to move large, heavy loads. Critical to ef- ranean roof supports (cover image), mining equipment actua-
ficient actuation of the hydraulic cylinder rod is the surface fin- tors and other non-marine environments primarily use iron-
ish of the piston rod, where consistently very low roughness based 431 stainless steel overlays applied by conventional
and minimal to no waviness are musts. Surface imperfections laser cladding or ultra high-speed laser cladding (EHLA).
as a result of corrosion and/or wear reduces the effectiveness
of the rod and can eventually lead to seizure and failure. Large (3 to 20 m length) marine hydraulic cylinders used for
offshore riser tensioners and other corrosive environment ap-
As such, the hydraulic piston rod surfaces have traditionally plications primarily use laser clad or EHLA overlays of nick-
been protected with hard chromium plating. However, the el-based Inconel 625 or cobalt-based Ultimet.
production of hexavalent chromium [Cr(VI)] during processing
has lead to environment and safety concerns with tough re- The current iron- and nickel-based overlays are highly crack
strictions imposed by government regulatory agencies. As a susceptible and normally require a costly preheating step.
result, hard chromium plating costs are increasing and the Even with preheating these legacy materials can crack easily
number of hard chromium processors decreasing globally. during processing which leads to downtime and expensive
This has caused many industries to seek alternative surface rework. Clearly, new materials are needed that have a wide
solutions to protect hydraulic cylinder rods that can meet the application window to eliminate cracking and the associated
cost and performance requirements demanded by the costly preheat. Further, these materials must provide better
market. wear resistance to increase hydraulic cylinder operational life.

The Oerlikon Metco Solution

Utilizing our unique Scoperta™ Rapid Alloy Development Metco 1720x materials series are intended for the harsh cor-
(RAD) technology, Oerlikon Metco has developed break- rosion environments that exist in marine applications. Over-
through solutions for protecting hydraulic cylinder rods from lays of Metco 1720x have corrosion resistance comparable
wear and corrosion that can be applied using standard laser to overlays of Inconel 625 or Ultimet.
cladding or EHLA processes. These solutions are optimized
for different conditions — for example, operation in atmo- Both Metco 1020x series and Metco 1720x series offer sig-
spheric (non-marine) versus marine environments. The mate- nificantly improved abrasion resistance while avoiding the
rials have environmentally-friendly cobalt-free compositions. potential cracking issues of their traditional overlay counter-
parts. As a result, they can extend the service life of a hy-
The Metco 1020x series is an iron-based composition devel- draulic cylinder rod and reduce maintenance and replace-
oped to protect hydraulic cylinder rods in non-marine environ- ment costs.
ments. Overlays of Metco 1020x series offers corrosion resis-
tance comparable to 431 stainless steel overlays.

Figure 1. Non-marine hydraulic cylinder rod applications include those found on Figure 2. Marine hydraulic cylinder rod applications include platform riser
the bucket excavator and earth-moving truck bed lift mechanism. Metco 1020x tensioners and on-platform cranes. Metco 1720x series products are ideal for
series products are ideal for these applications these applications

SF-0030.0 – Surface Solutions for Marine and Non-Marine Hydraulic Rods

© 2020 Oerlikon Metco 2
Solution Description and Validation
1. Application Requirements for Hydraulic
Cylinder Rods
Efficient functionality of hydraulic cylinder rods is dependent
upon the surface quality of the rod. Therefore, protective sur-
faces should have the following characteristics:
n Corrosion resistance equivalent or better than:
n 400-series stainless steel for non-marine applications
n Inconel 625 or Ultimet for marine applications
n Crack-free / defect-free overlay
n Applied in multiple layers
n Eliminate the need to preheat when cladding
Note: Many hardfacing materials do crack, which can
lead to additional corrosion.
n Abrasion resistance
n Overlay should provide both corrosion and abrasion Figure 3. To maintain the operational efficiency of hydraulic cylinder rods,
resistance protective surfaces must meet stringent requirements.
n Overlays must finish well to meet operating requirements
n Environment, health and safety concerns
n Eliminate hard chromium plating and Cr(VI)
n Avoid cobalt-based materials

2. The Benefit of Oerlikon Metco’s Scoperta RAD

A unique and important part of Oerlikon Metco’s material
Relative Corrosion Resistance

R&D toolkit is our Scoperta Rapid Alloy Development pro-

cess — a computational modeling aid that can quickly review
tens of thousands of potential compositions and ‘suggest’
candidate compositions for further empirical analysis.

This approach is a proven method that often leads to materi- Each dot is one
of approximately
al compositions with breakthrough service properties for the 60 000 calculated
alloys
application under investigation. It was used in the develop-
Relative Abrasion Resistance
ment of both the non-marine and marine hydraulic rod mate-
rials discussed in this document. Figure 4. Rapid Alloy Development (RAD) Modeling enabled the design
of new protective overlays for hydraulic rods in marine and non-marine
applications.

3. Solutions for Non-Marine Hydraulic Rod

Applications: Metco 1020x Series Materials
3.1 Design Intent and Properties of Metco 1020x Series
The Metco 1020x material series was developed to precipi-
tate a small fraction of hard phase in a corrosion resistant
matrix. The hard phase precipitates were engineered to form
isolated morphologies that provide an increase in abrasion
resistance and are not detrimental to the crack-resistance of
the overlay. (Figure 5).

One of the unique properties of the Metco 1020x series is that

overlays softer compared to 420 and 431 stainless steels, and
a popular competitive overlay, but laboratory testing shows it
is more abrasion resistant than those materials. (Figure 6). This
contradiction in properties was one of the design intents of the Figure 5. Typical microstructure of an overlay produced with Metco 1020A using
Metco 1020x series. a conventional laser cladding process..

SF-0030.0 – Surface Solutions for Marine and Non-Marine Hydraulic Rods

© 2020 Oerlikon Metco 3
 Hardness Comparison Abrasion Resistance Improvement (%)
700 1.8 2.50

Abrasion Resistance (ASTM G65A Normalized)

Abrasion Resistance (ASTM G65E Normalized)

1.6 2.25
600
48% 2.00
1.4 Better 71%
Vickers Hardness (HV300)

500 Better
1.75 145%
1.2 Better
1.50
400 1.0
1.25
300 0.8
1.00
0.6
200 0.75
0.4 0.50
100
0.2 0.25

0 0 0
Metco 420 S.S. 431 S.S. Competitor Metco 420 S.S. 431 S.S. Metco Competitor
1020A 1020A 1020A

Normalized Abrasion Resistance Improvement Using Metco

Overlay Alloy Hardness
ASTM G65A ASTM G65E 1020A Overlay

Metco 1020A 285 HV300 1.71 2.45 ---

420 Stainless Steel 570 HV300 1.15 --- ≈ 48 %
431 Stainless Steel 500 HV300 1.00 --- ≈ 71 %
Competitor 620 HV300 --- 1.00 ≈ 145 %

Figure 6. Comparison of hardness and abrasion resistance for non-marine protective overlays. While Metco 1020A overlays are softer than the stainless
steel and a popular competitive overlays, it clearly has significantly better abrasion resistance. Note: Abrasion resistance is based on normalized volume
loss where higher numbers in the graph are better.

Two versions of Metco 1020x are available that have been 3.2 Modeling Stable Matrix Phases
designed for different processes, as shown in the Table 1. A tool that can be used to predict the matrix phase in iron-
based alloys is the Schaeffler Diagram (Figure 7). By simply
Product Name Particle Size Dist. Process calculating the chromium equivalent and nickel equivalent of
Metco 1020A -150 +53 µm LC, PTA
the alloy based on its composition, one can use the
Schaeffler diagram to predict not only which phase(s) form
Metco 1020B -53 +20 µm EHLA
but also estimate the relative volume fraction of the phase(s).
Table 1. Available Metco 1020x series products.
LC = Conventional Laser Cladding; PTA = Plasma Transferred Arc Welding;
EHLA = Ultra High-Speed Laser Cladding
As shown on the Schaeffler diagram, the normal composi-
tional tolerances in 431 stainless steel can form any combi-
nation of martensite, austenite, and ferrite phases. Each
n Proprietary iron-based alloy developed using Oerlikon phase possesses different properties which contribute to the
Metco’s Scoperta RAD known problems of cracking and hardness variations in
n Patent pending 431stainless steel overlays. To avoid this issue, the Metco
n Manufactured in-house by Oerlikon Metco using gas 1020x series of materials was designed to form a 100% fer-
atomization ritic matrix phase as shown in the bottom right portion of the
n Spherical powder particles of consistent chemical Schaeffler diagram. Although ferrite is fairly soft and results in
composition low overlay hardness, it allows for a wide application window
n Similar overlay properties are produced using either con- and consistent properties in the coating.
ventional laser cladding or ultra high-speed laser cladding
n Overlays exhibit corrosion resistance similar to 431stain- To overcome the low hardness of ferrite, the material was en-
less steel gineered to precipitate hard phases that improve the abra-
n Overlays exhibit lower hardness but improved abrasion sion resistance of the overlay. The hard phases are engi-
resistance compared to 431 stainless steel neered to form small isolated precipitates and are
subsequently not detrimental to the crack susceptibility of
the material.

SF-0030.0 – Surface Solutions for Marine and Non-Marine Hydraulic Rods

© 2020 Oerlikon Metco 4
 Austenite
+
Austenite Ferrite
14
Austenite
+
Martensite te
rri
12 Fe te
5% rri
Fe e
10
% rrit
Fe e
20
% rrit
10 Fe
% e
40 rrit
Fe
%
60
Chromium Equivalent

e
rrit
8 Fe
80%
Martensite
431 e
rrit
Stainless %
Fe
6 Steel Austenite 100
Martensite +
+ Martensite
Ferrite +
4 Ferrite

Ferrite

2
Metco 1020x
Series
0
10 12 14 16 18 20 22 24
Nickel Equivalent

Figure 7. Schaeffler diagram used to model stable iron matrix phases. 431 stainless steel can form different matrix phases and volume fractions of those
phases based on composition tolerance and processing parameters. In contrast, Metco 1020x materials form a stable matrix allowing for a wide application
window and consistent overlay properties.

3.3 Corrosion Resistance

The corrosion resistance of overlays of Metco 1020 and 431
Stainless were tested via ASTM B117, ASTM G59 and
ASTM G61. As shown in Table 2, Metco 1020x overlays
demonstrated a performance similar to 431 stainless steel in
all laboratory tests. Based on these results it can be con-
cluded that overlays of Metco 1020x are at least as corrosion
resistant as 431 stainless steel overlays for these conditions.

ASTM G59/G61
ASTM B117 (< 0.01 mpy)
Overlay
Salt Spray Test
Alloy Tafel Linear
(1000 h)
Extrapolation Polarization
Metco 1020x Pass Pass Pass
Figure 8. Grinding a hydraulic rod to a high finish.
431 S.S. Pass Pass Pass

Table 2. Corrosion testing comparing overlays of Metco 1020x and 431

stainless steel

3.5 Summary: Metco 1020x Series

3.4 Finishing of Metco 1020x Series Overlays In conclusion, Metco 1020x overlays exhibit a wide applica-
Metco 1020B, clad via EHLA, finishes to customer standards tion window for producing a crack-free coating that has
when using grinding processes. Metco 1020x series overlays comparable corrosion resistance to 400 series stainless
have been successfully clad crack-free in all laser cladding steels and is more abrasion resistant than traditional 400 se-
trials without the need for preheating. ries stainless steels.

SF-0030.0 – Surface Solutions for Marine and Non-Marine Hydraulic Rods

© 2020 Oerlikon Metco 5
4. Solutions for Marine Hydraulic Rod
Applications: Metco 1720x Series Materials
4.1 Design Intent and Properties of Metco 1720x Series
Using a design strategy similar to that of the Metco 1020x
material series, overlays of Metco 1720x material series was
developed to exhibit higher abrasion resistance than tradi-
tional Inconel 625 or Ultimet overlays while maintaining a
crack-free coating that has similar corrosion resistance in
marine environments.

The key to this design is the precipitation of isolated hard

phases in a nickel-based, corrosion-resistant matrix (Figure
9). The introduction of the hard phases increases the abra-
sion resistance, but since the hard phases form an isolated
morphology, they are not detrimental to the crack-resistance Figure 9. Typical microstructure of an overlay produced with Metco 1720A using
of the overlay. a conventional laser cladding process..

These precipitates increase the hardness of the overlay relative

to the incumbent materials as measured by Vickers Hard-
ness indentation (hardness graph) which then translates to an Product Name Particle Size Dist. Process
increase in abrasion resistance as measured by ASTM G65-A Metco 1720A -150 +53 µm LC, PTA
(Figure 10). Metco 1720B -53 +20 µm EHLA

Table 3. Available Metco 1720x series products.

Two versions of Metco 1720x are available that have been LC = Conventional Laser Cladding; PTA = Plasma Transferred Arc Welding;
designed for different processes, as shown in the Table 3. EHLA = High-Speed Laser Cladding

Hardness Comparison Abrasion Resistance Improvement (%)

400 1.8
Abrasion Resistance (ASTM G65A Normalized)

350 1.6
25% Better
1.4
300 67% Better
Vickers Hardness (HV300)

1.2
250
1.0
200
0.8
150
0.6
100
0.4

50 0.2

0 0
Metco 1720A Inconel 625 Ultimet Metco 1720A Inconel 625 Ultimet

Overlay Alloy Hardness Normalized Abrasion Resistance Improvement Using

ASTM G65A Metco 1720A Overlay
Metco 1720A 375 HV300 1.67 ---
Inconel 625 280 HV300 1.38 ≈ 25 %
Ultimet 300 HV300 1.00 ≈ 67 %

Figure 10. Comparison of hardness and abrasion resistance for non-marine protective overlays. Metco 1720A overlays exhibit hardness and abrasion
resistance that is significantly higher traditional Inconel 625 or Ultimet overlays. Based on cladding trials, Metco 1720A can be expected to produce a
minimum hardness of 350 HV300. Note: Abrasion resistance is based on normalized volume loss where higher numbers in the graph are better.

SF-0030.0 – Surface Solutions for Marine and Non-Marine Hydraulic Rods

© 2020 Oerlikon Metco 6
n Proprietary nickel-based alloy developed using Oerlikon
Metco’s Scoperta RAD
n Patent pending
n Manufactured in-house by Oerlikon Metco using gas
atomization
n Spherical podwer particles of consistent chemical
composition
n Similar overlay properties are produced using either con-
ventional laser cladding or ultra high-speed laser cladding
n Overlays exhibit corrosion resistance similar to Inconel
625 and similar to Ultimet for hydraulic cylinder rod
environments
n Higher hardness and abrasion resistance compared to
Inconel 625 and Ultimet overlays
Figure 11. A finished hydraulic rod.
4.2 Corrosion Resistance
Corrosion testing, specifically ASTM B117, ASTM G59, Operators noted they did not have issues finishing the rods
ASTM G61 and ASTM G48, show overlays of Metco 1720x using processes equivalent to finishing standard nickel-based
material series have similar performance to Ultimet. overlays.

ASTM G59/G61
Metco 1720x series overlays have been
ASTM G48
ASTM B117 (< 0.01 mpy) successfully clad crack-free in all laser
Overlay Rm Temp, 40 °C
Salt Spray Test cladding trials without the need for
Alloy Tafel Linear Pitting
(1000 h) preheating.
Extrapolation Polarization Resistance
Metco 1720x Pass Pass Pass Pass
4.4 Summary: Metco 1720x Series
Inconel 625 Pass Pass Pass Pass
In conclusion, Metco 1720x overlays
Ultimet Pass Pass Pass Pass exhibit a wide application window for
Table 4. Corrosion testing comparing overlays of Metco 1720x, Inconel 625 and Ultimet producing a crack-free coating that has
comparable corrosion resistance and
After 1000 hours exposure to salt spray in the ASTM B117 better abrasion resistance than Inconel 625 and Ultimet,
test, the Metco 1720x overlay did not show any signs of rust making it well-suited for hydraulic rod applications in marine
or damage. This is similar to the performance of Inconel 625 environments.
and Ultimet overlays in this test.
5 Relevant Applications
ASTM G59 and ASTM G61 testing showed that the corro- The Metco 1020x and Metco 1720x series of materials are
sion rate of the Metco 1720x overlays are below 0.1 mpy suitable for all types of hydraulic cylinder rod applications to
which is in line with the results of the incumbent materials. replace hard chromium plating and other conventional pro-
tective overlays. Additional applications include:
The last test performed was the ASTM G48-A to determine n Dimensional Restoration
the pitting resistance of these overlays at room temperature n Hydroelectric valves
and 40 °C. At both temperatures, there was no pitting seen n Exhaust fans
on any of the samples indicating that the Metco 1720x over- n Cylinder liners
lays have similar pitting resistance to Inconel 625 and Ultimet n Pump plungers
in this corrosion environment (Table 4). n Bearing surfaces
n Pump seals
4.3 Finishing of Metco 1720x Series Overlays n Pump liners
Metco 1720B, clad via EHLA, finishes to customer standards
when using grinding processes.

SF-0030.0 – Surface Solutions for Marine and Non-Marine Hydraulic Rods

© 2020 Oerlikon Metco 7
Customer Benefits
Effective Efficient
n Improves on current protective overlays such as 400-se- n Product versions available with particle size distributions
ries stainless steels for non-marine environments and optimized for standard application processes (e.g., stan-
nickel-based or cobalt-based overlays (Inconel 625 and dard laser cladding, EHLA and PTA
Ultimet respectively) for marine environments n Produces crack-free overlays, enhancing corrosion
n Offers similar or better corrosion resistance resistance
n Offers significantly better abrasion resistance n Can be applied in multiple layers
n Finish grind to the high surface finishes needed for hy- n Materials allow a wide application window that provides
draulic rod applications highly reproducible overlays

Economical Environmental
n No additional processing steps required to apply Metco n Eliminates hard-chromium plating and Cr(VI)
1020x series or Metco 1720x series versus other iron- or n Cobalt-free compositions
nickel-based overlays
n Elimination of preheat lowers applications costs
n Improved abrasion resistance extends the service life of
cylinder rods and lowers operating costs

Inconel is a trademark of Huntington Alloys Corporation

Ultimet is a tyrademark of Haynes International, Inc.

Information is subject to change without prior notice.

SF-0030.0 – Surface Solutions for Marine and Non-Marine Hydraulic Rods www.oerlikon.com/metco
© 2020 Oerlikon Metco [email protected]