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Hardfacing alloys contain as base elements typically iron, nickel, or cobalt, to which metallurgists add varying amounts of carbon, chromium, molybdenum, tungsten, silicon, manganese, vanadium, and boron. To raise hardness, the primary property for wear resistance, alloy designers add elements that either form hard constituents (carbides, borides, or Laves phase), or that strengthen the matrix by going into solid solution. Carbon content determines toughness and abrasion resistance--as carbon rises, abrasion resistance increases and toughness drops. Chromium forms carbides, increases corrosion resistance, and adds high-temperature strength. Tungsten, a potent carbide former, also boosts high temperature strength, as does cobalt. Tougheners include nickel and manganese. Boron forms hard wear-resistance borides. The chart below, developed from results of Farm-A-Syst projects in Wisconsin, Minnesota, Arkansas, Maine and Louisiana, summarizes various water-quality hazards. "On more than 40% of the farms the petroleum storage area posed a high risk of pollution. That''s more than pesticides, fertilizer, livestock waste or any of the other potential sources," says tonka Jackson.New reasons for concernPetroleum fuels contain several toxic compounds, including benzene, toluene and xylene -- all considered carcinogens. A gallon of spilled gasoline contains enough benzene power to contaminate 2,000 cubic feet of soil or 10 million gallons of water. "Pressure at the fuel injectors tools has increased from 15,000 psi a few years ago to nearly 30,000 psi on new engines," says Pete Brown of Caterpillar''s engine applications group. "To get these higher pressures, fuel pumps are built to closer tolerances. Dirt in the fuel is like sandpaper, and it will definitely cause greater wear."To meet the challenge, Cat''s newest engines are equipped with increased water-sensing and fuel-filtering capabilities as well as a filter on the fuel tank breather. Primary fuel filters, once designed to remove 150-micron particles, are now rated for 10 microns. Secondary filters, once sized to remove 10-micron particles, are now rated for 2 microns. And the new high-efficiency filters can remove computer up to 99% of particles above those rated sizes compared to the 50% efficiency of older nominal filters. Filter improvements are also available for storage tanks. "Tank filters are typically rated at 10 microns nominal, so they take out 50% of particles greater than 10 microns in size. Tank filters with higher efficiencies, ratings down to 2 microns and water-absorbing capabilities, are now available," says Gall.
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