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The lightweight construction of steel structures is often limited by the mechanical properties of the weld metal. The strength values of modern base materials are not achieved in the weld metal. There is a considerable need to develop welding consumables that allow the processing of modern fine-grained structural steels without limiting their potential. The Physical Vapor Deposition (PVD) coating of welding wire electrodes can increase the strength of the weld metal of a Mn4Ni2CrMo welding wire electrode by up to 30%. By using different coating elements, the Hall–Petch relationship can be exploited and such an increase in strength can be achieved. Especially by applying titanium, vanadium, and yttrium coatings, the strength of the weld metal can be increased. Due to a multilayer structure of the coating, the weld metal and the process can be influenced independently of each other. The effects of mono-element coatings and multi-component coatings on the weld metal and the process are discussed. PVD coatings allow welding wire electrodes to be individually adapted to the requirements.

Development of surface coatings for high-strength low alloy steel filler wires and their effect on the weld metal microstructure and properties