This paper presents a new mechanism, observed directly for the first time, to explain low carbide fractions in Ni–WC overlays produced with GMAW. In this loss mechanism, a significant amount of powder loss is a consequence of the non-wetting behaviour of tungsten carbide. High speed videography and quantitative metallography of weld deposits are used to identify this mechanism. The non-wetting mechanism found acts simultaneously with the carbide dissolution mechanism, which until now was the only suggested cause of low carbide fraction in GMAW Ni–WC overlays. The non-wetting behaviour is observed in both short circuit and free flight metal transfer, accounting for carbide losses between 20 and 70% in the experiments performed. Low carbide fraction has prevented the mainstream use of GMAW for Ni–WC overlays, despite the advantages of simplicity, capability of in situ repair, and low capital costs. The findings presented here have a potential large impact for further consumable and process development.
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