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.

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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.

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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.

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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.

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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.

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Petrochemical Industry:

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

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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.

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

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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.

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

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Advantages of Cladding:

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

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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.

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

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