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The protection of machinery and structural components by thermal coatings is of huge economic importance. Each hour of downtime, caused by deficient coatings as a result of wear and corrosion, costs a fortune. Savings by reducing these downtime hours can be achieved by applying optimized functional coatings which show enhanced properties. The main welding processes for applying coatings are GMAW or OA, PTA or Laser, each with their pros and cons. The PTA process can be seen as the intermediate process bridging the low cost, high deposition rate and the expensive but high end Laser. Recently, the PTA and especially the laser process are gaining more attention and market shares. Nowadays the flux-cored wires can be upgraded more and more with for instance complex carbides and achieve coatings similar to the high performance coatings obtained by PTA and Laser welding but at much lower costs. The common problems accompanying the GMAW process: a large heat affected zone and dilution, can be circumvented by using the cold metal transfer (CMT), the AC-GMAWand the GMAW hot wire process, allowing the flux-cored wires to fully deploy their large potential and compete with the welding techniques. The current paper will describe the modern GMAW hot wire process and then deal with innovative materials and process concepts for the high performance flux-cored wire to give a competitive alternative for the PTA process and expensive laser. Rezime Zaštita mašina i strukturnih komponenti termičkim nabrizgavanjem je od ogromnog ekonomskog značaja. Svaki sat zastoja, uzrokovan nedostajućom prevlakom kao rezultat habanja i korozije, košta bogatstvo. Ušteda smanjenjem vremena zastoja može se postići primenom optimizovanih funkcionalnih nanosa koji pokazuju poboljšana svojstva. Glavni postupci zavarivanja za nanošenje su MIG/MAG ili otvorenim lukom OA, plazma PTA ili Laser, svaki sa svojim za i protiv. Proces PTA se može posmatrati kao srednji proces koji premošćuje niske troškove, veliku brzinu nanošenja između skupog ali visokoučinskog lasera. Nedavno, PTA i posebno laserski proces dobijaju više pažnje i tržišnih udela. Danas se punjene žice mogu sve više nadograditi sa, na primer, složenim karbidima i postižu se nanosi slični visokokvalitetnim nanosima dobijenim PTA i Laserskim zavarivanjem, ali uz znatno niže troškove. Uobičajeni problemi koji prate proces MAG: velika zona uticaja toplote i mešanje, mogu se zaobići korišćenjem hladnog prenosa metala (CMT), ACMAG i MAG sa vrućom žicom, čime se punjenim žicama omogućuje da se potpuno razvije njihov veliki potencijal i konkurišu tehnikama zavarivanja. Sadašnji rad će opisati savremeni MAG proces sa vrućom žicom, a zatim se baviti inovativnim materijalima i procesnim konceptima za punjene žice visokog učinka kako bi se dobila konkurentna alternativa za PTA proces i skupi laser. NAUKA∗ISTRAŽIVANJE∗RAZVOJ SCIENCE∗RESEARCH∗DEVELOPMENT 12 ZAVARIVANJE I ZAVARENE KONSTRUKCIJE, 1/2019, str. 11-21

Hardfacing material solutions for high performance coatings in wear and corrosion applications