Hardfacing and Overlay for Mining Wear Parts: Pick the Right Grade

November 2, 2026

Two wear parts can sit side by side on the same machine and still wear in completely different ways. One gets ground down by constant abrasion, and the other sees major impact until it chips. Hardfacing, also called overlay, adds a wear-resistant layer to the surface of a part so it lasts longer in service, but the grade that suits one part will not suit the other, and the wrong grade is how a part ends up back on the bench early. Raptor applies ARM ULTRA™, ProARM® and PTA HARDERCOAT™ robotic hardfacing at every Raptor CISC (Continuous Improvement Service Center), so the grade can follow the way your part actually wears.

Tell us the part and how it wears and we will spec the hardfacing. Request a quote

3 grades

ARM ULTRA™, ProARM® and PTA HARDERCOAT™

Every CISC

Hardfacing and overlay are available at every Raptor Continuous Improvement Service Center

Robotic

Applied robotically, with every pattern kept on file

Pick the hardfacing grade by how the part wears

Two things decide the grade: how fast the part wears and how hard it gets hit. Each card below rates the grade on both, and the line at the bottom says where it fits best.

Wear

High

Impact

Moderate

Best when: wear is high and impact is moderate.

Wear

High

Impact

High

Best when: wear is high and impact is high too.

Wear

Severe

Impact

Low

Best when: wear is severe and impact is low.

PTA overlay on a ripper tip

Which mining wear parts can be hardfaced

Overlay maximizes wear life on tips and adapters, cutting edges, bolt-on segments and plenty of other wear components you may have. PTA stands for Plasma Transferred Arc, a welding process that uses a plasma arc to deposit a wear-resistant layer, and it is the grade we reach for when abrasion is severe and impact is low. If you are not sure which grade your part needs, send us the part and tell us how it wears. We take it from there without cutting a corner on safety.

Hardfacing a worn part instead of replacing it

Many wear parts are changed out while most of the piece is still good. Bolt-on half arrows and reversible segments, for example, often come off with about 80% of the part in great shape. Overlay puts that remaining life back to work. Each CISC offers high volume overlay and low volume custom overlay depending on the job, and because we keep every pattern on file, we can adapt the pattern when conditions change instead of starting over. For more on the process, read about our robotic overlay services or visit our technologies page.

How a hardfacing job goes

Step	What happens
1. Pick the grade	Match the grade to how the part wears. If you are unsure, we will spec it.
2. Send us the part	Send the part and tell us how it wears. Photos help.
3. We apply the hardfacing	The overlay is applied robotically at a Raptor CISC, to a pattern we keep on file.
4. Back in service	The part goes back on the machine with its wear life restored.

Common questions

What is robotic hardfacing?

Hardfacing, also called overlay, adds a wear-resistant layer to the surface of a part so it lasts longer in service. Robotic hardfacing means a robot applies that layer to a pattern we keep on file, so the same part can be repeated when it comes back.

Which hardfacing grade should I choose?

Start with how the part wears. High wear with moderate impact points to ARM ULTRA™. High wear with high impact points to ProARM®. Severe wear with low impact points to PTA HARDERCOAT™. If you are not sure, tell us the part and how it wears and we will spec it.

What is PTA hardfacing?

PTA stands for Plasma Transferred Arc. It is a welding process that uses a plasma arc to deposit a wear-resistant layer on the part. We offer it as PTA HARDERCOAT™ for severe wear.

Which wear parts can be hardfaced?

Tips and adapters, cutting edges, bolt-on segments and plenty of other wear components. If you are not sure yours qualifies, send us the part.

Is it worth hardfacing a worn part instead of replacing it?

Often, when most of the part is still good. Bolt-on half arrows and reversible segments, for example, often come off with about 80% of the part in great shape, and overlay puts that remaining life back to work. If the structure is cracked or deformed, replacement may be the better call, and we will tell you.

Where is hardfacing available?

At every Raptor CISC (Continuous Improvement Service Center).

What should I send for a quote?

The part, how it wears, and photos if you have them. The more we have, the faster the answer.