Flux Cored Wire

Diffusion specializes in medium and high alloyed content Flux cored wires. It has a wide range of special FCW for joining, surfacing and Hardfacing including Nickel, Cobalt and aluminum wires. The formulation of various types of flux cored wires used for comprehensive range of wear plates is carefully designed to give a weld metal (overlay) that would provide extra long service life under a variety of harsh service conditions.

TYPETECHNICAL DATADESCRIPTION & APPLICATION
CORDIFF 49 Wire Diameter (mm): 1.6 2.0 2.4 2.8 Current (Amps) : 170-230 200-250 260-310 300-360 Voltage (V) : 23-26 24-27 25-28 25-30 Wire Stick-out (mm) : 25-30 25-30 35-45 35-45 A CrC type tubular wire for an abrasion resistant overlay on plain carbon steel, Hadfield manganese steel & gray cast iron. Deposit exhibits multiple hard phases, ensures resistance to low stress scratching abrasion. This wire is recommended for use in mining industries, cement mills etc.
CORDIFF 50 HARDNESS : 50-55 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 170-230 200-250 260-310 300-360 Voltage (V) : 23-26 24-27 25-28 25-30 Wire Stick-out (mm) : 25-30 25-30 35-50 35-50 A high carbon, high chrome, tubular wire depositing a weld metal having excellent abrasion resistance under moderately high impact. It is useful for build up of crusher parts, bucket lips & teeth. Multipass deposit is possible
CORDIFF 55 HARDNESS : 58-60 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-240 220-260 260-320 300-360 Voltage (V) : 24-26 25-28 28-30 28-30 Wire Stick-out (mm) : 20-30 20-30 35-45 35-45 A CrC type flux cored wire having excellent resistance to abrasion and moderate impact. Very much useful for the application to resist abrasion accompanied by corrosion. The resulting deposits cannot be heat treated, machined or forged.
CORDIFF 55 Mo HARDNESS : 56-59 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-240 220-260 260-320 300-360 Voltage (V) : 24-26 25-28 28-30 28-30 Wire Stick-out (mm) : 20-30 20-30 38-40 35-45 High C, Cr - Mo alloyed flux-cored wire electrode for hardfacing on parts that are exposed to high abrasive mineral wear. The weld deposit of this electrode has a higher temperature resistance (upto 450º C). Used for pumps, mixer parts, conveyor screws, tyres and liners of cement and power plants.
CORDIFF 59 HARDNESS : 59-61 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 170-230 200-250 260-310 300-360 Voltage (V) : 23-26 24-27 25-28 27-30 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 High C, Cr alloyed flux cored'wire that deposits a high chrome carbide weld metal with excellent resistance to abrasion and moderate impact. Deposits are non machinable.
CORDIFF 60 HARDNESS : 61-63 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-240 220-260 260-320 300-360 Voltage (V) : 24-26 25-28 28-30 28-30 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 High C, Cr - Nb alloyed flux - cored wire for severe abrasive wear. The weld deposit consists of chrome and niobium - carbides. Weld metal is non machinable. Maximum deposit should be limited to three layers. Very much useful for hardfacing various critical parts of mining equipments, cement and mineral industries.
CORDIFF 61 HARDNESS : 63-65 HRc Wire Diameter (mm): 1.6 2.0 2.4 2.8 Current (Amps) : 180-240 220-260 260-320 300-360 Voltage (V) : 24-26 26-28 28-31 27-30 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 High C, Cr -Nb-B-alloyed flux -cored wire with special carbides for extreme hardness. This combinatior results in high abrasion resistance. Very much suitable for the hardfacing of mining equipments, augers impellers and dredgers etc.
CORDIFF 65 Z HARDNESS : 63-65 HRc Hardness reduction : at 400º C app. 4% : at 650º C app. 10% Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-2430 220-260 260-320 300-360 Voltage (V) : 24-26 26-28 28-31 27-30 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 High C, Cr- Mo- Nb- V- W- alloyed flux - cored wire, which forms extremely hard carbides. This is used for hardfacing against extremely strong mineral wear. The deposit retains its wear resistance upto 650º C. This wire is recommended for use in sintering plants, augers, and blast furnace bells.
CORDIFF 70 T4 HARDNESS : 160 - 180 BHN Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 175-222 175-350 200-375 240-400 Voltage (V) : 23-27 24-28 25-28 26-30 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 Corodur 70 T4 is a tubular wire which produces a low alloyed deposit used for both joining and buildup. The weld metal has a high tensile strength and crack resistance. This special alloy is designed to join and buildup of machine bases, booms, shovel and agriculture equipment, wheels and supporting rollers.
CORDIFF 71 T1 TENSILE STRENGTH : 500 - 655 N/mm2 YIELD STRENGTH : 400 N/mm2(Min.) Elongation : 22% (Min.) CVN Impact (+20° C) : 47 J (Min.) Wire Diameter (mm) : 1.2 1.4 1.6 Current (Amps) : 110-180 130-220 160-250 Voltage (V) : 20-26 22-28 24-30 Specially developed flux cored wire for all positional welding, which gives radiographic weld metal quality with low hydrogen. It gives high deposition rate. Stable arc. Low spatter loss with easy slag removal. Suitable for welding mild and mild tensile steels. Wire can be use on general rusty and mill scale surface. Using 80%Ar/Balance CO2 or 100% CO2 as the shielding gas. Suitable for welding mild and mild tensile steels material such as St37-2, St- 52-3, St-35.8, St-45.8, and also for welding ship building steels, Bridges, Towers, Vehicles, Rolling stocks, Chemical parts and Macherinery, wagons, steel frame etc.
CORDIFF 71 T5 TENSILE STRENGTH : 525 - 655 N/mm2 YIELD STRENGTH : 425 N/mm2 Elongation : 22% (Min.) Wire Diameter (mm) : 1.2 1.4 1.6 Current (Amps) : 110-180 130-220 160-250 Voltage (V) : 20-26 22-28 24-30 Specially developed flux cored wire for all positional welding, which gives radiographic weld metal quality with low hydrogen. It gives high deposition rate. Stable arc. Low spatter loss with easy slag removal. Suitable for welding mild and mild tensile steels. Wire can be use on general rusty and mill scale surface. Using 80%Ar/Balance CO2 or 100% CO2 as the shielding gas. Suitable for welding mild and mild tensile steels material such as St37-2, St- 52-3, St-35.8, St-45.8, and also for welding ship building steels, Bridges, Towers, Vehicles, Rolling stocks, Chemical parts and Macherinery, wagons, steel frame etc.
CORDIFF 200 K HARDNESS (as deposited) : 180 - 200 BHN (work hardened) : 400 BHN Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-220 220-250 260-300 300-340 Voltage (V) : 24-26 25-27 25-27 26-28 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 The austenitic weld deposit of the highly alloyed flux - cored wire electrode is corrosion resistant, work hardening, anti - magnetic, heat and thermal shock resistant upto 850º C. Because of the high elongation (40%) the alloy is suitable for ductile buffer layers on old hardfacings and difficultto weld steels.
CORDIFF 203 HARDNESS : 200 BHN Tensile Strength : 63 kg / mm sq. A tubular wire ideal for general fabrication and build up prior to hard surfacing with a special flux including internal vapour phase shielding, which eliminates the need for external shielding gas. Suitable for fillet and butt welds, on site fabrication and maintenance.
CORDIFF 250 K HARDNESS (as deposited) : 220 - 250 BHN (work hardened) : 450 - 500 BHN Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-220 220-250 260-300 300-340 Voltage (V) : 24-26 25-27 25-27 26-28 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 Austenitic high manganese and chromium alloyed flux cored wire electrode, The fully austenitic weld deposit is corrosion resistant, non - magnetic, has high plasticity and acts as a buffer, especially on old hardfacing. Deposits are work hardening upto 500 BHN. The deposits resist shrinkage, strees and high impact loading.
CORDIFF 300 HARDNESS : 280 - 325 BHN Wire Diameter (mm): 1.6 2.0 2.4 2.8 Current (Amps) : 180-220 220-250 260-300 300-340 Voltage (V) : 24-26 25-27 25-27 26-28 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 A low alloyed flux - cored wire electrode for building up applications that can be used for multi - layer welding because the weld metal is crack - free and ductile. Deposits are machinable with carbide tools. Used primarily on tractor wheels, steel shafts, gear and trunion, rail links etc.
CORDIFF 308 L TENSILE STRENGTH : 57 kgf/mm 2(Min.) Elongation (L=5d) : 35% (Min.) Wire Diameter(mm) : 1.2 1.6 2.0 2.4 2.8 Current(Amps) : 120-200 180-230 220-250 260-300 300-340 Voltage (V) : 21-25 24-27 25-28 26-28 27-30 Polarity : DC+ Specially developed C-Cr-Ni stainless steel flux cored wire with high alloying content, which produces bright and smooth bead. Due to the presence of Ferrite, the weld metal has lower susceptibility to cracking. Better intergranular corrosion resistance as carbon content is low. For welding and joining of austenitic stainless steel 304, 304L, 308L and 18-8 type steels and alloy steels. Also recommended for tough and wear resistant overlays on all steels.
CORDIFF 309 L TENSILE STRENGTH : 60 kgf/mm2 (Min.) Elongation : 30% (Min.) Wire Diameter (mm) : 1.2 1.6 2.0 2.4 2.8 Current (Amps) : 120-200 180-230 220-250 260-300 300-340 Voltage (V) : 21-25 24-27 25-28 26-28 27-30 Polarity : DC+ Specially developed C-Cr-Ni-Mo stainless steel flux cored wire with high alloying content, which produces bright and smooth bead. Such as stainless steel to mild steel. Stable and smooth arc, with very good slag detachability. For welding and joining of austenitic stainless steel 301, 302, 304, 305, 308 and 309 type stainless steel. Also recommended for tough and wear resistant overlays on all steels.
CORDIFF 324 TENSILE STRENGTH : 70 kgf/mm2(Min.) Elongation : 20% Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-220 220-250 260-300 300-340 Voltage (V) : 24-26 25-28 26-28 27-30 It is a specially developed flux cored wire with high alloying content, which produces bright and smooth bead. Chemistry is so controlled; the ferrite-austenite duplex structure provides resilience with very high strength. It is used for High strength, crack resistant joining of unknown and dissimilar steels, Hadfield High Carbon and alloy steels. Also recommended for tough and wear resistant overlays on all steels.
CORDIFF 341 TENSILE STRENGTH : 80 kgf/mm2(Min.) Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 170-230 220-260 260-330 300-360 Voltage (V) : 22-26 24-27 25-29 27-30 Specially developed flux cored wire with alloying content of C, Cr and Mo which offer a tough microstructure, specially suitable as a buffer layer and for heavy build up. Weld deposit exhibits high tensile strength, adequate creep rupture strength, and good impact toughness. Used for base layer build up of Roller Press Rolls. Also suitable as a buffer layer and for heavy build up, Impact proof, Frogs, Coarse crusher, Crusher Jaws, HP Rolls, Rails, Beaters.
CORDIFF 356 (SA WIRE) HARDNESS : 40 - 42 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 160-260 240-280 280-340 320-400 Voltage (V) : 20-26 22-26 24-27 25-28 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 High Cr, Ni, Mo, Nb, V - alloyed wire. The welding deposit is resistant to corrosion, impact and heat. Best results are achieved by 2-3 layers. Exclusively developed for application like continuous casting rolls etc.
CORDIFF 362(SA WIRE) HARDNESS : 40 - 47 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 160-240 220-260 260-340 300-370 Voltage (V) : 22-26 22-27 24-28 25-30 It is a Cr, Ni, Mo alloyed tubular wire. The welding deposit is highly suitable for welding on tough, corrosion resistant continuous cast rolls and also wear parts from the steel industry and large machinery. Exclusively developed for applications like continuous casting rolls, Bridge store, depositions to thick areas of water, steam and gas fittings for 0 operating temperatures to 450 C; rope pouring roles; on alloying buffer layers.
CORDIFF TT 400 HARDNESS : 55 - 60 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 170-230 220-260 260-330 300-360 Voltage (V) : 22-26 24-27 25-29 27-30 A specially developed tubular wire electrode, which produces highly alloyed deposit for hardfacing of parts subject to extreme wear and impact. The alloy primarily consists of primary Cr carbides and other complex carbides. It gives an extremely wear resistant weld metal with standing intermediate strength of Impact. Used for hardfacing on parts subjected to extreme wear and impact. Screens, wear plates etc.
CORDIFF 440 HARDNESS : 450 - 500 BHN Wire Diameter (mm) : Current (Amps) : Voltage (V) : Wire Stick-out : 25-30 25-30 38-40 35-45 Tubular wire depositing a martensitic steel. The deposit has good high temperature abrasion resistance and corrosion resistance. Applications include hot strip mill table rolls, pinch rolls, concast rolls etc.
CORDIFF 450 HARDNESS : 43 - 45 Hrc Wire Diameter (mm) : 2.4 2.8 Current (Amps) : 260-300 300-340 Voltage (V) : 25-27 26-28 Wire Stick-out : 38-40 35-45 Very similar to Corodur 400 with higher hardness. For base materials with higher carbon content a buffer layer or preheating must be employed. Applications are wheel rims, chain links, bucket chains etc.
CORDIFF 480 NBS HARDNESS : 58 - 62 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 170-230 220-260 260-330 300-360 Voltage (V) : 22-26 24-27 25-29 27-30 Welding Parameters : Current : DC+ A tubular wire CORDIFF 480 NBS deposits a high C-Cr-Nb alloyed weld metal used for hardfacing which gives excellent resistant to extreme abrasive wear. Weld deposit consists of chrome and niobium carbides which offers an excellent resistance to abrasion. Good results are achieved by welding in two layers. Used for Hardfacings on parts for coal mining equipment, steel industry, cement industry and mineral industries.
CORDIFF 502(SA WIRE) HARDNESS : 48 - 51 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 160-260 240-280 280-340 320-400 Voltage (V) : 20-26 22-26 24-27 25-28 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 Tubular wire depositing a weld metal similar to 440 but more alloyed. Applications include concast rolls, pinch rolls, hot strip mill table rolls etc. Excellent corrosion resistance and resistance to thermal fatigue.
CORDIFF 600 OA HARDNESS : 53 - 56 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-220 220-250 260-320 300-350 Voltage (V) : 24-26 25-27 25-28 27-30 It is a tubular wire which produces a Cr Mo V alloyed deposit. The weld metal has high hardenability and produces a hardness up to 56 Rc even with relatively slow cooling rates. Crack resistance is good provided adequate preheat and interpass temperature are applied together with slow cooling after welding. Resistance to tempering is good. Best choice for intermediate hardfacing layer for Roller Press Rolls. Parts subjected to abrasion, impact and compressive loads, sand pumps, dredge pump parts, dredge ladder rolls, etc.
CORDIFF 600 TIC HARDNESS : 56 - 58 Hrc Wire Diameter (mm): 1.6 2.0 2.4 2.8 Current (Amps) : 180-220 220-250 260-300 300-340 Voltage (V) : 24-26 25-27 25-27 26-28 Wire Stick-out : 25-30 25-30 38-40 35-45 C, Cr, Ti and Mo-alloyed wire electrode for parts that are exposed to high abrasive wear in combination with impact stress. The micro structure of the deposit is martensitic with Titanium - carbides. Exclusively recommended for cement crusher rolls, pulveriser rolls and hammers.
CORDIFF 601 HARDNESS : 56 - 60 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-220 220-250 260-300 300-400 Voltage (V) : 24-26 25-27 25-27 26-28 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 Corodur 601 is a tubular wire. It deposits Cr-Mo- W-V alloy. Deposits have high hardenability and give hardness upto 60 HRC even on slow cooling. Resistance to tempering is good. Best suited for abrasion, impact, compressive loads, sand pump, pump parts, tool joints etc.
CORDIFF 603 HARDNESS : 46 - 48 Hrc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-220 220-250 260-300 300-400 Voltage (V) : 24-26 25-27 25-27 26-28 Wire Stick-out (mm) : 25-30 25-30 38-40 35-45 Cr, Mo, V, W-alloyed flux cored wire with excellent properties to resist abrasion and impact. The welding deposit has a high hot hardness upto 550º C. Very much suitable for sealing area of blast furnace bells.
CORDIFF 801 ER HARDNESS : 60 - 67 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-240 220-260 260-320 300-360 Voltage (V) : 22-26 23-28 25-30 26-31 Welding Parameters : Current : DC+ It is a specially developed tubular wire electrode, which produces highly alloyed deposit of Fe-C-Cr-Ni-B and other special alloyed elements.The alloy primarily consists of carbides, borides and other complex carbides. It has excellent toughness for this high hardness range. Application includes Hardfacing on parts of coal mining equipment, cement, steel and mineral industries subjected to fine particle erosion.
CORDIFF 814 HARDNESS : 44 - 48 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-220 220-250 260-300 300-340 Voltage (V) : 24-26 25-27 25-27 26-28 A flux cored wire electrode, depositing a rich Cr-Ni-Mo-V weld metal containing lower carbon content. Excellent for building up the working face of composite hot forging dies, both large as well as small. The deposit has excellent wear resistance at elevated temperatures, very good hot strength and thermal shock resistance. Thermal shock and heat resistant flux-cored wire electrode for maintenance and to increase the service life of hot working tools, e.g. hot forging dies, etc..
CORDIFF 2455 HARDNESS : 45 - 55 HRc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 170-230 220-260 260-330 300-360 Voltage (V) : 22-25 24-27 25-29 27-30 Welding Parameters : Current : DC+ It is highly alloyed C-Cr-Mo-Ni-Nb-W tubular wire for abrasive wear, erosion and impact even at elevated temperatures. The weld deposit with Nickel rich matrix specially developed for high corrosion and abrasion with erosion wear, good impact resistance at this hardness without the danger of chipping off, and high temperature resistance. It is used for Blast furnace bells, fire graters, crusher, sinter wheel breakers, smelter loading chutes, Hardfacings on parts for coal mining equipment, cements and minerals industries etc.
CORDIFF 4015 (SA WIRE) HARDNESS : 220 - 240 BHN A tubular wire depositing a martensitic stainless steel weld metal, exhibiting good high temp, strength, corrosion resistance and thermal fatigue resistance. Applications include valve sealing surfaces, bridge bearings, slide ring sealings, valve concast rolls etc. wherever temperature of about 550º C, corrosion and metal to metal abrasion are involved.
CORDIFF 4351 HARDNESS : 38 - 42 Hrc Wire Diameter (mm) : 1.6 2.0 2.4 2.8 Current (Amps) : 180-220 220-250 260-300 300-340 Voltage (V) : 24-26 25-27 25-27 26-28 Wire Stick-out : 25-30 25-30 38-40 35-45 A newly developed flux cored wire provides tough and corrosion resistant overlay against wear from sea water plant and power plant operation. Very much suitable for protecting parts in chemical, food and paper industries.

TECHNICAL DETAILS FOR CORDIFF FLUX CORED WIRES (OPEN ARC TYPE)
Size (mm) 1.6 2.0 2.4 2.8
Current in Amps 180-200 220-250 260-300 300-340
Voltage (V) 24-26 25-27 25-27 26-28
All Diffusion make FCW (OA Type) deposited through wire feeder machine require no separate shielding gas. The wire flux
content ensures deposition consistency over a wide range of conditions. Increase in voltage produces flatter beads.
Excessive spatter indicates the need to reduce voltage. Reduced amperage assists minimum dilution and penetration.

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