Abstract: Disclosed are methods of facing a surface of a weldable iron based material with a consumable iron based electrode and alloy forming elements by creating an electric arc between the electrode and the surface of the weldable base material effective to form a weld puddle of which the weldable base material provides from about 35% to about 80% by weight, and preferably a major portion, of the weld puddle formed by the electrode and the base plate and by depositing and melting a predetermined quantity of alloy forming elements in the weld puddle to form an alloy abrasion resistant or corrosion resistant facing. Also disclosed are plates having abrasion or corrosion resistant surfaces in which from about 35% to about 80% and preferably a major portion of the weld puddle formed by the electrode and the base material is the weldable iron based material.

Abstract: Disclosed are methods of hardfacing and hardfaced tool joints used for connecting together drilling pipe for drilling bore holes in the earth, such as drilling to possible oil and gas formations. The hardfacing is welded to the outer surface of the box member of the tool joint and forms a surface harder than silicious earth particles but a surface which does not cut casing through which the drilling pipe and tool joints move. Hardfacing alloys having the foregoing properties contain primary carbides in a matrix which are present in an amount to form a plurality of cracks of not less than one in 3 inches on cooling from molten to solid state are satisfactory. Such cracking causes no damage to the box member, provides an indication of the primary carbides present and hence the abrasion resistance of the hardfacing and provides a long wearing service life for the box member.

Abstract: An improved feeder for feeding particulate materials to a weld zone wherein the particles of different materials fed are in desired proportions to each other at any cross-section of the outlet device, the feeder converting an intermittent feed to a continuous homogeneous flow and having dispersal apparatus positioned within the feeder so that welding material to be fed to the weld zone must pass through the dispersal apparatus.

Abstract: A feeder for feeding alloy materials and electrode wire to a weld zone for deposition in desired amounts including a plurality of independent feeding elements, each feeding element controlled by its own independent control, the feeding elements powered by motors which are independent of the motor used to feed the electrode wire to the weld zone.

Abstract: Disclosed are methods of producing hardfaced plate which eliminates distortion while making weld deposits along the length of a sheet-like plate of relatively ductile and weldable material by securing the plate about a cylindrical supporting surface, then welding hardfacing material to the plate's surface which causes the plate to shrink against and be supported by the cylindrical surface which effectively maintains the plate against substantial distortion during the welding. The plate with the welded hardfacing material is then removed from the cylindrical surface. Preferably, the composition of the hardfacing material is such as to form random cracks at a frequency of not less than about one in each three inches upon cooling from the welding temperature, and preferably of the order of about 5/8" to about 3/4".

Abstract: Bulkwelding is disclosed in which a consummable electrically conductive electrode is fed to a weld zone, and electric current is caused to flow in the electrode thereby providing a magnetic field about the electrode, particles of magnetically responsive weld material are fed to the electrode which magnetically adhere to it, fluxing materials are fed to the weld zone, preferably in front and in back of the electrode and adhered weld particles, and the electrode with the particles of weld material magnetically adhered to it are fed through the flux to the weld zone where the electrode and particles are melted to form the weld. The rate of feeding the weld particles and the electrode are coordinated to provide any desired ratio of weld particles to electrode in the weld. Both methods and apparatus are disclosed.