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WELD OVERLAY TECHNOLOGY

Weld overlay, also known as hard facing, is a critical technique applied to combat the severe abrasion and wear that equipment can experience during service. Rozen's Wear Division has the latest in Robotic Weld Overlay Equipment. We have four welding head straight machines to increase production, robotic Bend equipment to weld 3D and 5D bends and we can operate two stations’ simultaneously to weld, concentric and eccentric reducing pump spools. 

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Cladding is a crucial process in the maintenance and manufacture of components in industries where corrosion and wear are significant concerns. It not only improves the service life of the parts but also contributes to the efficiency and safety of industrial operations.

Our Weld Overlay Procedures are designed to meet or exceed all industry Specifications.

Pipe diameters of 6”- 60” can be delivered in 40-foot lengths. We offer 3D and 5D bends with weld overlay in pipe sizes between 24” to 60". 

  • Chromium carbide alloys

  • Tungsten carbide

  • Complex carbide

  • Stellite

  • Various stainless-steel alloys for corrosion and abrasion resistance

CLADDING PROCESS & APPLICATIONS:

 

Hydro Transport Pipes:

Pipes used in the hydro transport of slurries are subject to extreme abrasion from the solid particles in the mixture. Weld overlay can be applied to the interior surfaces to increase resistance to wear alloys.

Tailings Lines:

Similar to hydro transport pipes, the pipelines that carry mine tailings (the waste material after the mineral has been extracted) can also be protected with a weld overlay to extend their service life.

Mining Buckets:

The buckets used in mining operations to move ore and waste material are subject to both impact and abrasive wear. A weld overlay with a hard, abrasion-resistant material can protect these buckets and reduce the need for frequent replacements.

Cladded Plates for Mining Equipment:

Various components such as chutes, hoppers, and wear liners in mining equipment can be manufactured from cladded plates. These plates have a tough inner core with a hard facing layer on the surface to resist abrasion.

Oil and Gas Industry:

Protects pipelines, manifolds, and other components from corrosion due to sour gas, saline water, and other corrosive substances found in oil and gas exploration and processing.

Petrochemical Industry:

Cladding is used to protect reactors, columns, and pipes from corrosive chemicals used in the process of making petrochemicals.

Power Plant Equipment:

In power plants, especially those involved in the generation of energy from fossil fuels, cladding is used to safeguard boiler tubes and other components from high-temperature corrosion and erosion.

 

 

Manufacturing Cycle for Cladded Parts:

 

1. Preparation: The base material is prepared, often by machining to the correct shape and cleaning the surface to ensure a good bond.

2. Cladding: The chosen cladding process is applied to deposit the protective layer on the base material.

3. Post-Cladding Operations: These may include heat treatment to relieve stresses induced by the cladding process and to homogenize the microstructure of the clad layer.

Machining or finishing operations to achieve the final dimensions and surface finish requirements.

4. Quality Control: Inspections such as non-destructive testing (NDT) are performed to ensure the quality of the clad layer and the bond integrity.

Advantages of Cladding:

Extended Life Span: Cladding extends the life of components by protecting them from corrosive and abrasive environments.

Cost Efficiency: It is often more cost-effective to clad a component with a thin layer of expensive corrosion-resistant material than to manufacture the entire component from the same material.

Customization: Cladding allows for the customization of surface properties while maintaining the desired mechanical properties of the base material.

Resource Efficiency: Reduces the need for scarce materials by only using them where necessary.

Chrome Carbide Overlay Testing includes but not limited to:

  1. Chemical Analysis: Cr >25%, C>3%, Carbide Volume Fraction (CVF) >35%

  2. Deposit Hardness > 510Hv10

  3. Overlay Surface Hardness > 510Hv10

  4. Overlay thickness: 8.0mm + 2.0mm/-0.0mm for double pass weld overlay

  5. Metallographic Examination, Primary carbides>35% volume, underbead cracking and Planar Cracking: crack length <30% of the bead width, as observed along the length of the weld coupon.

  6. Surface smoothness: +2.0mm/-0.0mm

  7. ASTM G65 Abrasion Test: <0.18g loss at 25% and 75% depth.

  8. AITF Rotary Impact Test: <3.0g after 3600 cycles ( 24minutes)

  9. AUT Automated UT <30% the max allowable % of underbead cracking/ disbondment

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