AbstractThe wear resistance and durability of 40 mm thick·high chromium iron weld surfacing deposits have been investigated with reference to the low stress abrasion conditions experienced by the work roll of a coal crushing mill. It was found that an underlayer of austenitic stainless steel greatly reduced cracking and spalling of the deposit. The variations in welding conditions tested had relatively little effect. A modified ASTM G65 dry sand/rubber wheel abrasion test with a 3 kg load was shown to give results that correlated well with service experience. Extensive compositional testsindicated that carbon content was the lnajor factor controlling hardness and abrasion resistance, through its influence on chromium carbide volume fraction. The optinlum carbide content was found to be 55-65%, since above this range brittle fracture becomes excessive.