• Publisher-DOI

The degradation of pump components by corrosion and complex, simultaneous damage mechanisms, e.g., erosion–corrosion and cavitation–corrosion leads to high costs through replacement and maintenance of parts. To increase the lifetime of cost-efficient components with superior casting properties, surface welding of duplex stainless steel on gray cast iron parts was performed using inert shielding gas metal arc surface welding (GMA-SW) and plasma transferred arc surface welding (PTA-SW). The thermal conductivity of the used shielding gas and the preheating temperature influenced the dilution of the surface layers, which had a major impact on the corrosion resistance and the microstructure. Lower cooling rates enhanced diffusion and lead to precipitation of carbides. High heat input and prolonged cooling times during surface welding resulted in high dilution and a carbide network. The corrosion resistance in artificial seawater of those surface layers was substantially reduced compared to surface layers with lower heat input and higher cooling rates. The corrosion of the surface layers in the potentiodynamic polarization test was driven by selective corrosion of the phase boundary between Cr–carbides and Cr–depleted austenite. Passive behavior was observed for surface layers with low dilution, which had homogeneous chromium distribution and no carbide networks. In conclusion, the corrosion behavior of gray cast iron was improved by surface welding with duplex stainless steel. The corrosion resistance of the surface layers produced with PTA-SW with no preheating exceeded that of the surface layers produced with GMA-SW and came close to those of a commercially available duplex stainless steel used as reference material.