Weld overlay/cladding

 

Solutions for orbital cladding and automatedweld overlay 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.

Cladding with TIG and TIGer process

To increases the durability of these highly exposed parts, their surfaces are protected by a welding overlay 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.
  • Orbital 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 TIG Hot Wire cladding. The basic principle involves the juxtaposition of two TIG arcs, organised 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 preheated wire, warmed up using the Joule effect via the energy of a third current source, supports the specific profile of formed the weld pool helps improve the efficiency of the entire procedure in a sustainable way.
  • Depending on the requirements, it is possible to optimise the thickness of the layers to within a range between 1.5 and 3.5 mm. 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 6 kg/h i.e. about three times more than the TIG 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 % from the second layer.

 

A machine fitted with the TIGer technology will prove its profitability allowing a 20 to 50 % drop in operating costs per kilogram of weld metal.

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