weld overlay vs cladding

In most industrial scenarios, a mechanical bond will suffice but what about when it doesn’t? Laser cladding isn’t your only metallurgically bonded option, outside of spray and fuse thermal spray. We often hear the terms “cladding” and “weld overlay” used synonymously – and while the two terms are related, they do differ. For more information about PTA Welding, check out our other blog post: Plasma Transfer Arc Welding for Abrasion Resistant Coating or check out the welding services that HTS Coatings offers. Laser cladding and weld overlays vary greatly in heat input and the resulting coatings vary slightly in thickness capabilities and materials. Each of these processes produces an overlay that is metallurgically bonded to the substrate. Materials are type 304L stainless steel and medium-carbonsteel. On the other hand, Weld overlay is a welding process. Clad plate for subsequent forming into vessel shells was produced by weld overlaying in the early development days, but nowadays overlaying is directly applied to the completed vessel shell, or to vessel dished ends, vessel cylinders or individual strakes, and this latter aspect FIGURE 3. Weld Overlay Cladding is a process that involves metallurgically bonding a Corrosion Resistant Alloy to the surface of a Base Metal providing it with corrosion resistant property. In some alloy combinations, dilution of the weld overlay material by the steel requires that more than one weld pass is required. While some customers have precise engineering specifications that denote cladding, other customers may need to weigh their options to decide what will allow them to achieve their project goals. Choosing a homogenous exotic material to manufacture the V-Cone may be similar in price, and depending on the material requirements it may also lessen the lead time for manufacturing. MIG welding can be difficult to maintain consistent temperature and arc, requiring skilled craftsmen to create a quality overlay. A weld overlay is a type of cladding that uses a welding process to melt a material onto the surface of another, different material. We often hear the terms “cladding” and “weld overlay” used synonymously – and while the two terms are related, they do differ. Weld overlay melts one metal—the cladding layer—onto the surface of another metal of similar composition and melting point, forming a clad metal material that is resistant to corrosion and wear. Current qualification procedures for weld overlay cladding involve measurement of bulk dilution and ensuring that it is below a maximum level and also passing a standard generic corrosion test such as ASTM G48. These metals are typically more expensive than their corrosive alternatives, so cladding is a cost-effective method of providing corrosion-resistance compared to the price of manufacturing a homogenous flow meter. CRA Weldoverlay Cladding. Laser cladding has a slightly wider range at 0.008 inches to 0.15 inches thick. This is normally done to improve the material by adding either a corrosion resistant or … Sponsored Content. READ MORE. TIG welding, along with PTA welding and laser cladding, can apply the popular overlay metal, Stellite® 6 and other cobalt based alloys, as well as the nickel and tungsten carbide-based alloys of the Colmonoy® alloys, including Colmonoy® 88. Each of the weld overlays range in thickness from approximately 0.05 inches to about 0.1 inches. 1 Chemical Cleaning MIG (Metal Inert Gas) welding, or GMAW (Gas Metal Arc Welding), uses electricity, a shielding gas and a consumable electrode. These variables can of course be eliminated by careful planning and tooling when applying harface weld overlays. This is especially helpful in applications experiencing sand or rock particulates in the flow which may damage certain metallic surfaces. As it was mentioned in Clause 2 of the current paper, the typical requirement for corrosion resistant overlay is to obtain alloy 825 (UNS N08825) chemistry at the level of 3 mm from the top of the cladding surface. TIG weld overlay, while slower than PTA weld overlay, is faster than MIG weld overlay and can be done in most positions, although overhead welding can be difficult and requires highly skilled operators. MIG weld overlay cannot be done on vertical or overhead surfaces. HAZ is the zone of the substrate metal that has not melted but, has been subjected to the elevated temperatures of the process for a brief period of time. Hayden Laser Services 31 Conventional Thermal Spray Processes HVOF – High Velocity Oxy Fuel Premium mechanical bond (exceeds 10,000 psi) least amount of porosity Differential Pressure Flow Meters, Flow Meter Materials, Industrial, Oil & Gas | V-Cone. Obtaining 825 overlay in 1 layer. February 02, 2021. The goal of weld overlay is ultimately to improve the properties of the base metal. Corrosion resistant weld overlay and hard facing weld overlay. If the meter’s interior has been cladded but the exterior is still the base material, corrosion from seawater, extreme temperatures, abrasion from desert sand, or other environmental factors may affect the integrity of the meter’s construction. This all enables the ability to achieve very thin hardfacing overlays. PTA welding is the fastest overall with a skilled operator. Weld overlay pipe cladding has the advantage of versatility over other types of pipe cladding methods. VM V-Cone®: When is a Differential Pressure Meter Best for Municipal Applications? Weld overlay may also be referred to as cladding, hard facing, weld cladding or weld overlay cladding. We asked the engineering experts at McCrometer to weigh in on the similarities and differences between cladding and weld overlay, and here’s what you need to know! You’ll find many uses for Waldun’s wide range of Inconel alloys. TIG welding provides good temperature control while PTA welding and laser cladding provide excellent control over their process parameters. 4.1 Overlay thickness restriction factors. Weld Overlay Vs Explosion Bonded Cladding - posted in Industrial Professionals: Dear all, I need help please. Weld overlay is used for corrosion resistance or wear resistance and can be applied to extend the service life of new parts. August 25, 2014 Weld Overlay Vessels. We’re able to help you weld many types of Inconel to your parts and machines. Each process is performed differently, with laser cladding being the most different in application. Press the space key then arrow keys to make a selection. The V-Cone is an investment meter that requires minimal-to-no maintenance and offers up to ±0.5% accuracy throughout its proven 25+ year lifespan. 20x (e) Roll Bonding Process steps in cold roll bonding Steel body panel Mechanical Cleaning Fig. McCrometer can clad with a variety of materials such as duplex stainless steel, Inconel, nickel alloys, and other materials from the nickel and steel families. Many industrial processes cause damage to piping and fittings by the continuous assault of corrosive and abrasive media. Choosing a selection results in a full page refresh. The Oil and Gas Industry is very familiar with the use of cladding to mitigate corrosion in pipelines, flanges and other components used in the extraction of hydrocarbons. When it comes to overlaying capabilities, PTA is the most comparable to laser cladding; but that does not discount the other two. Cladding’s main purpose is to act as a protective cover to the base metal. The engineering experts at McCrometer weighed in on the similarities and differences between cladding and weld overlay, and here is … A general arrangement drawing for a V-Cone cladded with Inconel. Metal cladding or weld overlay is a similar process that is commonly used in several metal working processes. Despite having the highest heat input, PTA has the next best HAZ. He mentioned that this is based on the feedback received from various vessel vendors Your advise is very valuable. Dissimilar Metal Joining Techniques. We asked the engineering experts at McCrometer to weigh in on the similarities and differences between cladding and weld overlay, and here’s what you need to know! These more expensive materials ensure the longevity of the meter and the pipeline as a whole, as high-quality corrosion-resistant metals can withstand the harsh conditions of numerous oil and gas applications. Laser cladding and weld overlays also result in extremely wear resistant coatings. Expert advice on the suitability of weld overlay combinations. Typically, it provides a barrier coating to corrosive environments and is designed to protect the substrate. It does, however, still have the highest heat input of the weld processes, so heat distortion can still be a concern since it is performed at approximately 50,000°F. So, let’s take a look at how laser cladding compares to the different hardface weld overlay process on the market today. This alters the molecular structure of the metal in this area and it no longer possesses the desirable properties of the substrate material, but since it has not melted, it hasn’t assumed the properties of the solidified, overlay. As nouns the difference between cladding and overlay is that cladding is (rare) clothing; clothes while overlay is (printing) a piece of paper pasted upon the tympan sheet to improve the impression by making it stronger at a particular place. This means that the overlay material and the substrate material fuse together at a molecular level. This is due to the faster cooling and quenching of the overlay material. Cladtek provides weld overlay solutions to pipes, elbows, tees, fittings and flanges of almost any size. Cladding is the broad term for applying one material over another to provide a coating or covering. Each of the weld overlays range in thickness from approximately 0.05 inches to about 0.1 inches. Laser cladding is typically a robotically controlled process which provides unparalleled consistency but also limits it in deposition rate and positioning. McCrometer’s engineering experts also recommend fabricating the meter’s pressure taps from the same material as the cladding; protecting your meter and piping is important but neglecting a critical point such as the pressure taps leaves your meter vulnerable to that corrosion. A huge advantage of Laser Cladding is something called Heat Affected Zone, or HAZ. One main difference, cladding can be applied via mechanical (rolling or explosive) or by fusion welding methods. The actual weld overlay process used depends on many factors including access, welding position, the alloy applied, and economics. The names may be similar, but each meter has a unique construction and design, different product specs, and value-rich features that different customers favor. A more recent type of welding process, PTA (Plasma Transfer Arc) Welding, is the similar to TIG welding in raw materials but instead of a rod filler material, it uses a powder material and a specialized nozzle to ionize the shielding gas and create a plasma arc to apply the material to substrate surface. Welding Type. Even some operations managers flowing steam or super-heated steam may opt for a cladded meter so they don’t need to worry about the minimal carbon steel corrosion that’s likely to happen in that application. Differences Between Cladding and Weld Overlays Weld Overlay vs. Cladding Thickness. Weld overlay melts one metal—the cladding layer—onto the surface of another metal of similar composition and melting point, forming a base material that is resistant to corrosion and wear. Each process has specific benefits and limitations in respect to deposition rate, positioning and the control of process variables. Cladding vs. Weld Overlay: What’s the Deal? McMag 2000 vs. McMag 3000: What’s the Difference. a machine part surface. commonly asked weld overlay questions Weld overlay is a welding process where one or more metals with specific characteristics are applied to a base metal to im-prove desirable properties or to restore the original dimension of the component. Our contractor has proposed to use explosion bonded cladding for vessel plate with thickness (>50mm) instead the specified Weld overlay or roll bonded clad. ... brazing, weld cladding, weld overlays and centrifugal casting. Weld overlaying is commonly used to clad the surfaces of fabricated steel structures. It can be applied to an entire component, or only to specific areas of concern. So, while each process has its pros and cons, they all produce high quality, corrosion and wear resistant coatings. Pipes and flow meters can be clad through a variety of methods, the most popular being weld overlay, allowing the base material to be completely protected from corrosion or harsh chemicals by a metallic alloy welded onto the base material. Again, traditional overlay processes can be used as listed above. All of these use various heat sources to apply metallized coatings. Weld Overlay (WOL), also known as cladding, hardfacing, weld cladding, or weld overlay cladding, is a process where one or more metals are joined together via welding to the surface of a base metal as a layer. Waldun’s Inconel overlay and cladding services will definitely improve your machines and equipment. Laser cladding excels when heat distortion is an issue for smaller parts or parts made of heat sensitive metals. We strive to extend the life of equipment through repairing or manufacturing quality components. The main difference between cladding and weld overlay is that weld overlay (by codes and standard definition) is deposited by a fusion welding process, and not applied by … Roll Bond. Stainless Steel Cladding and Weld Overlays / 109 CLAPDING METAL ~.~ I (a) (b) Sintering Fig.3 Bond zone pattern typical of explosion-clad metals. MIG welding is the most limited, only applying steels and stainless steels, nickel, flux cored wire and hardface wires. As the world’s largest CRA weld overlay pipe manufacturer, Cladtek has substantial cladding capacity. McCrometer customers operating in the oil and gas industry often choose to have their large line size V-Cones made of carbon-steel and cladded with a nickel alloy, Inconel, or even stainless steel. It is particularly used to supply a degree of thermal insulation and weather resistance while improving the appearance of buildings. Weld overlay cladding is a process that provides protection for metallic components by welding a layer of corrosion-resistant alloy to areas at risk of corrosion and wear. The oil and gas industry, a popular market for the V-Cone, often has highly corrosive media flowing through pipes, such as crude oil and gasses like hydrogen sulfide. Each of the weld overlay types are relatively similar with small but significant differences between them. In situations where temperature isn’t an issue and laser cladding might be overkill, weld overlays provide an economical, hardfacing solution. Explosive Welding. Laser cladding, since it requires the lowest heat input of each of these processes, has the smallest HAZ. Customers in industrial markets will often decide to clad their meter if they are flowing a media with corrosive fluids or debris particulates. Cladding and Overlay. With the right weld head, this method can clad the interiors of tubing as small as 1.7 centimeter (cm) interior diameter and pipes as large as 80 cm in interior diameter. We recommend reaching out to the McCrometer factory to speak to our experts; having a discussion with our engineers can provide you with valuable information on our processes, available options, and factors like cost and turnaround time. Solutions for automated cladding operations used in manufacturing and maintenance. Laser cladding is the use of electrically produced laser light to heat wire or powder material and apply it to a substrate surface. This has many advantages including the decreased surface porosity that results in high performance, corrosion resistant coatings. Laser cladding has a slightly wider range at 0.008 inches to 0.15 inches thick. PTA welding and Laser cladding can also apply other stainless steels such as 300 and 400 series stainless steels. Weld overlay cladding provides protection against corrosion and wear for process and pipeline equipment. This HAZ is a weakened layer that affects the hardness and porosity of the underlying microstructure. Blog Home » Cladding vs. Weld Overlay: What’s the Deal? Other popular methods include hard-facing, which utilizes a spray or explosion-bonding process to increase the hardness of a surface. Use left/right arrows to navigate the slideshow or swipe left/right if using a mobile device, Plasma Transfer Arc Welding for Abrasion Resistant Coating, the welding services that HTS Coatings offers. Stacking Transmitters: Getting the Most Out of Your V-Cone, Flow Meters for Agriculture Applications: An Overview. As a customer considering cladding, the best thing you can do is provide the McCrometer factory with as much information about your application and flow project as possible so our team can prescribe a solution that will provide you with the most longevity and value for your investment. Inconel happens to be a popular choice with our oil and gas customers as it resists just about every corrosive fluid and media. Meters have gotten a negative reputation because historically, they’ve been implemented only when resources are limited, and... Oftentimes in municipal flow applications utilities and districts opt for a propeller meter, an electromagnetic (mag) meter, or another type of “no moving parts” meter like an ultrasonic device. Weld overlay solutions for customers’ free-issue components as well as the manufacture of complete components. In most waste heat recovery systems and boilers, the heat transfer tubes are usually made of … When it’s regarding flow meters, it’s the process of applying a better metallic surface over another surface to improve the properties, usually corrosion-resistance. The terms “cladding” and “weld overlay” are often used synonymously — and while the two terms are related, they do differ. The application of one material over another as a protective layer or skin is called cladding. Weld overlay is needed in a number of industry sectors where service conditions require corrosion resistant properties. As verbs the difference between cladding and overlay Laser cladding and weld overlays also result in extremely wear resistant coatings. Base materials including carbon steels, Duplex, Super Duplex, low alloy steels and stainless steel. Weld Overlay (WOL), also known as cladding, hardfacing, weld cladding, or weld overlay cladding, is a process where one or more metals are joined together via welding to the surface of a base metal as a layer.This is normally done to improve the material by adding either a corrosion resistant or hardfacing layer to it. We are able to do this on a variety of overlay materials such as 3-400 Grade SS, Alloy 400, Alloy 825, Alloy 625, Stellite and more. We do this to the best of our abilities, using innovative ideas and practical experience. While protecting the meter from the process fluid is typically the main reason for cladding, there’s also the outside environment to consider as well. However, there are instances in which a differential pressure (DP) meter... We’ll let you in on a secret – the difference is more than just a number! Carbon Steel Material with Stainless Steel Cladding. Cladding vs. Weld Overlay: What’s the Deal? TIG (Tungsten Inert Gas) welding, also referred to as GTAW (Gas Tungsten Arc Welding), uses the same raw materials except that, instead of a consumable electrode, it uses a nonconsumable tungsten electrode and an additional rod of the overlay material. If the flow project calls for a small line size V-Cone, the material cost savings won’t be significant if you choose to clad. Cladding is a weld overlay process yielding an entirely new surface that can be used with a large variety of overlay materials in different forms such as powder, wire, or cored wire. Hot roll bonding is the general process used. However, just as the price of the meter increases when the line size increases, so do material costs. . Weld overlay/cladding. Weld overlay cladding (WOC) – also known as weld cladding or weld overlay – is a welding process in which a thin layer of metal is deposited over a base metal to improve its properties. The world of metallurgy involves numerous fascinating and innovative operations in order to add to the productivity and to improve efficiency. Ensuring that corrosion doesn’t diminish the V-Cone’s value and continual benefits is required to maintain optimal production in your flow application. This consumable electrode is typically the material used to overlay the substrate. Our workshop is equipped with computerized horizontal GTAW welding systems for cladding line pipes and spool pieces up to 12 meters in length, and computerized vertical pulsed hot-wire GTAW welding systems to clad a wide range of fittings, flanges, valve bodies, pressure vessels, etc. Material and weight savings may be gained when a clad, high strength, quenched and tempered steel is used in a corrosive environment. Typically weld processes with a higher heat input have a larger heat affected zone. All of the weld overlays; MIG, TIG and PTA, can produce coatings similar to laser cladding with PTA being the closest by far. While you won’t find "hardfacing" in the dictionary, it’s an industry standard word that anyone looking to repair and remanufacture their machine parts would benefit to know. When deciding to clad, a few factors should be considered. TIG welding can also apply 316 stainless steel, carbon steel and other wire metals. Weld overlay cladding process provides protection for products such as pipes, valves, flanges and specialist fabrications used in any hostile environment. This describes anything from thermal spray to laser cladding to weld overlaying. The changing regulatory environment has made flow meter implementation more popular in many agricultural and turf irrigation applications. The most black and white difference between the four process is the materials it can overlay. –Hardface weld overlays since 1974 –PTA weld overlays since 1988 –Laser cladding since 2007 Hayden Corporation Background . Cladding is a process where you would apply a different, tougher material than the base metal or surface. The weld clad process can be applied to extend the service life of new parts, or refurbish parts that have corroded or worn surfaces. For more information, contact the factory. A weld overlay is performed to protect the base material from wear or corrosive environments. The Mag Meter Tech Specs Despite... MktoForms2.loadForm("//app-sj17.marketo.com", "358-OTE-421", 1462); © Copyright 2021 McCrometer, Inc. | 3255 West Stetson Avenue, Hemet, CA 92545 USA | +1-800-220-2279 | Fax +1-951-652-3078. Hardfacing is any metalworking process where harder or tougher material is applied to a base metal i.e. In a previous post we compared laser cladding to thermal spray and briefly described the difference between a mechanical and metallurgically bonded coating. Weld overlay/cladding. The Inconel weld cladding and overlay services Waldun offers are of a high standard. McCrometer’s V-Cone® product suite is highly customizable in both exotic material construction as well as cladding, allowing the V-Cone to fit a wide range of customer applications.

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