Solutions for automated cladding operations used in manufacturing and maintenance
Many industrial processes cause damage to piping and fittings by the continuous assault of corrosive and abrasive media. In oil and gas production for example, components are severely eroded by the friction of sand; chemical apparatuses suffer from direct contact with aggressive substances. These phenomena are often boosted by elevated process temperature and pressure.
To increases the durability of these highly exposed parts, their surfaces are protected by cladding with more resistant materials.
- Cladding is applied whenever a long service life is expected from expensive components or when the workpiece cannot be produced entirely from the proper wear-resistant material.
- Cladding of piping and manifolds is common in petrochemical industry applications and for power plant equipment; in the aeronautic industry, components for aircraft engine components are also often reinforced using this process.
- Invented in 2013, the TIGer bi-cathode weld overlay technology is the outcome of a technological development by POLYSOUDE, a variant of GTAW Hot Wire cladding. The basic principle involves the juxtaposition of two GTAW arcs, organized and controlled to be combined into one single arc with the calorific value of the combination of both powers, but with characteristics which are unusual for such intensities.
- The addition of the wire, preheated using the Joule effect via the control of a third current source, enables the special profile of the weld pool to be used and to considerably improve the efficiency of the procedure.
- Depending on the requirements, it is possible to optimize the thickness of the layers to within a range between 1.5 and 3.5mm. This flexibility enables the quantity of weld metal to be adjusted to strict requirements and thus significant savings can be made, taking into account the costs of filler products (generally the noble alloys). The welding speed can run over 1.700 mm/min with deposition rates from 2.5 to 6kg/h i.e. about three times more than the GTAW Hot Wire technology.
- Complete control over dilution is provided with a rate of around 12% on the first layer and from 1.5 to 2% on the second layer.