In modern industrial wear-protection systems, Flux-Cored Wire (FCW) is the most advanced and versatile material for creating high-performance hardfacing layers. It is widely used to extend the lifetime of equipment exposed to abrasion, erosion, impact, corrosion, thermal wear, or high-pressure conditions.
With POP (Powder Overlay Process) technology, BCC/KOVI is the only manufacturer in Vietnam fully mastering the entire process:
from alloy design → powder formulation → strip rolling → wire forming → finished flux-cored wire.
This enables complete material independence, customized solutions, and precise control over performance.
WHAT IS FLUX-CORED WIRE? – THE MATERIAL BEHIND HIGH-PERFORMANCE HARDFACING
Flux-cored wire is a specialized welding wire consisting of:
- A steel alloy strip (outer sheath)
- A core filled with alloy powders formulated for specific wear mechanisms
- Adjustable ratios between strip thickness and powder composition
This structure allows BCC/KOVI to engineer hundreds of wire types—something impossible with conventional electrodes.
Key Advantages of Flux-Cored Wires
✔ 2–5× higher deposition rate than stick electrodes
✔ Accurate alloy composition and consistent metallurgical structure
✔ Produces specialized hardfacing layers (high-carbide, self-hardening, extreme erosion resistance)
✔ Compatible with MIG, FCAW, SAW, and gas-shielded or self-shielded processes
✔ Fully customizable under POP alloy-design framework
POP TECHNOLOGY – THE CORE PLATFORM THAT ENABLES BCC TO MANUFACTURE ADVANCED FCW
POP (Powder Overlay Process) is the technological foundation that allows BCC to:
▪ Design customized alloy compositions
BCC adjusts:
- Alloy ratios
- Powder particle size
- Carbide types (CrC, NbC, VC, WC…)
- Work-hardening behavior (Mn-series)
▪ Produce wire tailored for each industry and wear mechanism
Because BCC is not dependent on imports, the company can:
- Develop industry-specific or even equipment-specific FCW
- Localize formulas for Vietnam’s operating conditions
- Respond quickly to urgent maintenance demands
▪ Integrate materials – welding technology – wear-surface engineering
POP unifies powders, electrodes, flux-cored wires, wear plates, and surface-engineering technologies into one system.
As a result, BCC/KOVI hardfacing layers ensure:
- Precise hardness as designed
- Correct microstructure
- Minimal defects
- 2–10× longer service life, depending on application
INDUSTRIAL APPLICATIONS OF BCC/KOVI FLUX-CORED WIRES
BCC’s FCW is used widely in:
🟥 Cement Industry
- VRM rollers & tables
- Buckets & elevator systems
- Pump housings & impellers
- Feed chutes & liners
🟥 Thermal Power Plants
- Coal rollers & grinding components
- Fans, ducts, and high-temperature surfaces
- Wear protection at 400–900°C
🟥 Mining & Quarrying
- Bucket teeth & lips
- Screen plates & liners
- Conveyor pulleys & rollers
🟥 Steel & Metallurgy
- Steel-mill rollers
- Draw rolls and guide pulleys
- Guide rails and sheaves
🟥 Chemical & Petrochemical
- Corrosion-resistant hardfacing
- High-temperature components
🟥 Other Industries
- Hydropower
- Ceramics & construction materials
- Agricultural processing equipment
BCC/KOVI'S KEY FLUX-CORED WIRE SERIES
▪ Mn-Series – Work-Hardening (Heavy Impact)
-
D2546, D4048, D8547
▪ Low–Medium Alloy (Friction & Pressure Wear)
-
D3056, D5062
▪ Tool-Steel Based (Abrasion – Heat – Erosion)
-
D5553, D6550
▪ High-Carbide Series (Severe Abrasion & Erosion)
-
D4063, D6565, D6566
▪ Corrosion & Heat-Resistant (410–430 Stainless Series)
-
D4101, D4142, D4203, D4304
▪ Nickel-Based (Inconel / Superalloy Applications)
-
D11036
▪ Cobalt-Based (Extreme Heat & Thermal Shock)
-
D8047
▪ Cast Iron Repair
-
D2018
ADVANTAGES OF USING BCC/KOVI FLUX-CORED WIRES
1. 2–10× Longer Service Life
Optimized alloy design ensures layers engineered for each wear mechanism.
2. 20–40% Lower Maintenance Cost
Reduced shutdown frequency and improved asset reliability.
3. 2–5× Higher Welding Productivity
Higher deposition rate compared with SMAW.
4. European–AWS Standard Quality Control
Consistent metallurgy and operational reliability.
5. Local Manufacturing – Fast Delivery
No import dependency → ideal for urgent repairs.
CONCLUSION
Flux-cored wire is the central material in modern hardfacing, rebuilding, surface restoration, and wear-resistant engineering.
Combined with POP technology, BCC/KOVI delivers a truly integrated solution—from alloy development to finished hardfacing performance.
This enables industries to:
- Increase equipment lifetime
- Reduce maintenance costs
- Improve operational continuity
- Handle extreme wear conditions reliably
BCC/KOVI proudly stands as Vietnam’s only full-cycle manufacturer capable of designing, producing, and deploying advanced flux-cored wires for heavy industry.
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