In summary, cladding offers benefits such as improved corrosion and wear resistance. Cladding contributes to the longevity of equipment. This prolonged equipment life, in turn, positively impacts the environment by reducing material consumption in manufacturing, promoting energy efficiency, lowering emissions, minimizing waste, and conserving valuable resources.
Corrosion Resistant Overlay (CRO) provides a protective barrier against corrosive substances, extending the lifespan of equipment exposed to harsh environments. H2S, hydrogen sulfide, CO2, alkaline, methane.
Hard Facing Overlay (HFO) enhances the surface hardness, reducing wear and tear on components subjected to friction, abrasion, or erosion. Pistons, sand wash, mud, grit product.
The protective layer formed with cladding shields equipment from chemical exposure, preventing degradation and maintaining performance. Pitting Corrosion, Hydrogen Attack, Intergranular Corrosion, Microbial Induced Cracking.
Cladding can improve the equipment’s ability to withstand extreme temperatures, ensuring stability and functionality in challenging operating conditions. High Temperature oil cracking, coke furnaces, trash burning, waste heat recovery.
Components subject to abrasive forces, such as those in mining or manufacturing, benefit from cladding by increasing resistance to abrasive wear. Drill bits, shaft collars, blades, and buckets.
Longer-lasting equipment means less frequent replacement, reducing the need for raw materials and minimizing the environmental impact of production. Reduces material and mining costs by using lesser steels as the base metal and the weld overlay takes on the functionality of the ideal alloy.
Less corrosion and less wear improves efficiency and life expectancy equipment, contributing to overall energy conservation and sustainability efforts. It also reduces downtime and manpower needed to service the equipment.
Extended equipment life decreases the frequency of manufacturing and disposal, reducing the associated emissions, leaks and risks of environmental pollutants.
Longer equipment lifespan results in fewer discarded components, minimizing the amount of waste generated and promoting responsible waste management.
Sustainable equipment practices, facilitated by increased longevity, contribute to the conservation of natural resources by optimizing the use of materials and reducing the need for replacements
Weld overlay is a method to add a protective layer to a metal surface. In simple terms, it’s like giving a metal object a strong and durable coating that increases its lifespan. This extends a part’s service life, protects the environment, and helps reduce lifecycle costs. Weld Overlays are used in industries where surfaces undergo significant stress or environmental challenges.
Here’s How It Works:
Gas Tungsten Arc Welding, or GTAW is a welding process that forms an electric arc between a tungsten electrode and the base metal being welded. The electric current is Pulsed, rhymically increasing and decreasing amps to limit how deep the weld penetrates into the base metal. The welding wire is preheated to make the welding faster, e.g. increase deposition rate.
The purpose of weld overlay is to create a protective layer on the metal that prevents wear, corrosion, galling or other forms of damage.
The pulsing feature allows for more control over the welding process. It lets the welder adjust the heat input and quality of the protective material with greater precision.
In a nutshell, GTAW Hot Wire Hotwire is a cladding technique that adds a tough layer to metal surfaces, making metals more resistant to wear and corrosion through welding.
Weld Overlay is synonymous with cladding. Weld overlay layers the surface of a metal to protect it from corrosion, abrasion and prevent wear. Alloys like Inconel, Stellite, Stainless Steel, and even Hastelloy are on a metal part, producing sealing surfaces, permanently sealing machined features and quick connections and autoclave ports. Ideal for making corrosion resistant and leak-proof seals for sensors, flowlines and male-female pipe sealing connectors
Bore Cladding is a layer of weld that protects interior features from fluid flow, like the inside of a valve, an elbow, a weldneck flange or block. Inconel, Monel, Stainless Steel and even Stellite can be welded inside the bore to create a protective layer throughout. In industry, parts made with complete bore cladding are commonly called HH trim. Cladded Bores protects against abrasion and corrosion caused by severe chemicals flowing throw them. This extends the life of the components. Often used in machinery, HH Trim valves, components or pipelines benefit with extended longevity, improving design lifes from years to decades. This includes Wet-H2S sour service, and CO2 Sweet Service.
Pipe Cladding shields the interior of pipes from flowing chemicals for several yards or meters-worth of pipe joint. In service, it can be dozens of feet long or dozens of miles, depending on the application. GTAW Hot Wire Cladding welds the inside of a pipe, often for it’s full length, end-to-end. Enhances the pipe’s resistance to corrosion and wear from the inside out. Allows the pipe to be tailored to environmental factors and the inside to be tailored to the product flowing through it. Commonly used in high risk, severe H2S service, methane production, alkaline production, natural gas production with CO2.
