{"id":7591,"date":"2020-10-20T16:21:48","date_gmt":"2020-10-20T16:21:48","guid":{"rendered":"http:\/\/www.westermans.com\/blog\/?p=7591"},"modified":"2026-01-09T16:04:33","modified_gmt":"2026-01-09T16:04:33","slug":"description-of-the-weld-clad-overlay-process","status":"publish","type":"post","link":"https:\/\/www.westermans.com\/blog\/description-of-the-weld-clad-overlay-process\/","title":{"rendered":"What You Need to Know About Weld Cladding &amp; Overlay"},"content":{"rendered":"\n<p><span style=\"font-size: revert;\">In many industries, crucial parts are exposed to harsh, demanding conditions. Metal fabricators need a way to prolong the life of these parts, avoiding costly repairs and damage. That can often lead to catastrophic results in industries like construction, and oil and gas.<\/span><\/p>\n\n\n\n<p>*Updated January 2025*<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span data-preserver-spaces=\"true\">Key Takeaways:<\/span><\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li><span data-preserver-spaces=\"true\">The weld overlay and cladding process provides critical protection for vulnerable fittings.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Welding overlay is a process that applies one or more additional metals to the base metal using fusion welding. These materials are mainly chosen for their corrosion resistance and are applied to improve the base material&#8217;s properties.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Weld cladding can use either fusion welding or other mechanical forms like hot rolling to apply an additional material layer. This metal should have high-strength properties to improve this in the base material.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Industries that benefit from these critical processes include heavy industry, mining, oil and gas, and renewable energy.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">The equipment consists of a mechanised welding torch, mounted onto a carriageway to apply the metal overlay. Workpieces are handled precisely by a welding manipulator like a <a href=\"https:\/\/www.westermans.com\/weldingpositioners.aspx\" title=\"See more about welding positioners\">positioner<\/a> to ensure accurate results.<\/span><\/li>\n<\/ul>\n\n\n\n<p>&nbsp;<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span data-preserver-spaces=\"true\">Table of Contents<\/span><\/h2>\n\n\n\n<ol class=\"wp-block-list\">\n<li><span data-preserver-spaces=\"true\">The difference between overlay welding and clad welding.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">What is welding overlay?<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">What is weld cladding?<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Applications and industries that utilise these processes.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Equipment needed to perform weld cladding and overlay.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">New technology for weld cladding and overlay machines.<\/span><\/li>\n<\/ol>\n\n\n\n<p>&nbsp;<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span data-preserver-spaces=\"true\">What is the Difference Between Weld Overlay and Cladding?<\/span><\/h2>\n\n\n\n<p><span data-preserver-spaces=\"true\">Both weld cladding and overlay form a heavy-duty, metallurgically-bonded protective layer that will not be undermined or dislodged in service. They are critical processes in many industry sectors, where service conditions require corrosion-resistant properties. Although similar, there are subtle differences in each process.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">In overlay welding, one or more metals of similar properties are fusion welded to the base layer. These additional materials are chosen for their corrosion resistance, improving this function in the base material.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">Cladding welding, however, is applied to increase the strength of the base metal, reflected in the high-strength materials used in this process. While weld overlay uses materials similar to the base metal, weld cladding is also suitable for dissimilar metals. As well as <a title=\"Learn more about fusion welding from TWI\" href=\"https:\/\/www.twi-global.com\/technical-knowledge\/faqs\/what-is-fusion-welding\" target=\"_blank\" rel=\"noopener\">fusion welding<\/a>, weld cladding can <\/span><span data-preserver-spaces=\"true\">also<\/span><span data-preserver-spaces=\"true\"> be applied using other mechanical methods like <a title=\"What is hot rolling?\" href=\"https:\/\/www.corrosionpedia.com\/definition\/637\/hot-rolling\" target=\"_blank\" rel=\"noopener\">hot rolling<\/a>.<\/span><\/p>\n\n\n\n<p>&nbsp;<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span data-preserver-spaces=\"true\">What is the Weld Overlay Process?<\/span><\/h2>\n\n\n\n<p><span data-preserver-spaces=\"true\">The highly versatile weld overlay process provides the practical combination of readily available base materials, coated with a suitable corrosion-resistant&nbsp;alloy to protect any given area.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">Fusion welding methods used for overlay welding include MIG (metal inert gas), TIG (tungsten inert gas), SMAW (shielded metal arc welding), and other forms of arc welding like SAW (submerged arc welding).<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">One of the main benefits of this process is the cost savings. It enables you to use an inexpensive metal, such as carbon steel, for fabrication, applying a more expensive but corrosion-resistant layer of stainless steel afterwards.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">Typical welding alloy materials include Inconel 625, Inconel 825, Monel, Hastelloy, stainless steel, nickel and chromium.<\/span><\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"\/images\/user\/image\/weld%20cladding.jpg\" alt=\"\"\/><\/figure>\n\n\n\n<p><span data-preserver-spaces=\"true\"><strong><\/strong><\/span><\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span data-preserver-spaces=\"true\">What is Weld Cladding?<\/span><\/h2>\n\n\n\n<p><span data-preserver-spaces=\"true\">Used to improve the strength of a metal component, welding cladding is the process of applying a high-strength alloy layer to a base metal.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">Like weld overlay, the process can be applied using fusion welding, or other mechanical methods like hot rolling or powder metallurgy. You can also use dissimilar materials, unlike those used in overlay welding. <\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">Clad welding offers material and weight savings when a high-strength, quenched and tempered steel is used in a corrosive environment. Improving the strength of the component, weld cladding helps protect against general operational damage like friction, abrasion, and heat stress.<\/span><\/p>\n\n\n\n<p>&nbsp;<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span data-preserver-spaces=\"true\">Weld Cladding Overlay Applications and Industries.<\/span><\/h2>\n\n\n\n<p><span data-preserver-spaces=\"true\">A wide range of applications can benefit from these forms of metal overlay. <\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">The anti-corrosion advantages of overlay welding make it perfect for use in industries like subsea, petrochemical, and oil and gas. <\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">Applied to components including pipes, flanges, and valves, welding overlay not only reduces manufacturing costs but also helps to prolong the life of these critical parts.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">Offering the same advantages, clad welding is used where material strength is paramount. Applications like manufacturing boiler tubes and pipes and industrial pipelines benefit from its strengthening ability. Plus specialist fabrications for hostile environments like engine rooms and mines also take advantage of its capability to protect against abrasive damage.<\/span><\/p>\n\n\n\n<figure class=\"wp-block-image\"><a href=\"https:\/\/www.westermans.com\/wp-content\/uploads\/2020\/10\/cladding.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"600\" height=\"400\" src=\"https:\/\/www.westermans.com\/wp-content\/uploads\/2020\/10\/cladding.jpg\" alt=\"Weld Cladding\" class=\"wp-image-9600\" srcset=\"https:\/\/www.westermans.com\/blog\/wp-content\/uploads\/2020\/10\/cladding.jpg 600w, https:\/\/www.westermans.com\/blog\/wp-content\/uploads\/2020\/10\/cladding-300x200.jpg 300w\" sizes=\"auto, (max-width: 600px) 100vw, 600px\" \/><\/a><\/figure>\n\n\n\n<p><span data-preserver-spaces=\"true\"><\/span><\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span data-preserver-spaces=\"true\">Equipment Used in Clad Welding and Overlay<\/span><\/h2>\n\n\n\n<p><span data-preserver-spaces=\"true\">Overlay welding machines and clad welders are built of multiple components to form the final system.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">For overlay welding, these can be bespoke depending on the job requirement, but will all feature:<\/span><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><span data-preserver-spaces=\"true\">A welding manipulator, designed to handle the weldment during the overlay process.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">A Control unit to apply the desired program according to the job inputted by the operator.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">A Carriageway or similar, such as a column and boom or beam welding system, to facilitate the travel of the welding head.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">A welding torch that applies the weld overlay.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">A welding power source, such as a hot wire tig, or MIG welding machine, depending on the requirements of the project.<\/span><\/li>\n<\/ul>\n\n\n\n<p><span data-preserver-spaces=\"true\">In weld cladding operations, the component is mounted on a turntable, with the bore to be welded centred on the turntable rotational axis. <\/span><span data-preserver-spaces=\"true\">During the cladding operation, the turntable rotates <\/span><span data-preserver-spaces=\"true\">and<\/span><span data-preserver-spaces=\"true\"> the welding torch is stationary (moving up once a revolution). <\/span><span data-preserver-spaces=\"true\">A conventional&nbsp;<\/span><a class=\"editor-rtfLink\" href=\"http:\/\/www.westermans.com\/columnandboom.aspx\" target=\"_blank\" rel=\"noopener\"><span data-preserver-spaces=\"true\">column &amp; boom<\/span><\/a><span data-preserver-spaces=\"true\"> (rack &amp; pinion type) supports precision cross slides attached to the end of the boom.&nbsp;<\/span><span data-preserver-spaces=\"true\">The slides perform the task of moving the torch in two or more axes.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">A typical weld cladding system consists of:<\/span><\/p>\n\n\n\n<ol class=\"wp-block-list\">\n<li><span data-preserver-spaces=\"true\">A rack &amp; pinion drive type&nbsp;<\/span><a class=\"editor-rtfLink\" href=\"http:\/\/www.westermans.com\/ColumnAndBoom.aspx\" target=\"_blank\" rel=\"noopener\"><span data-preserver-spaces=\"true\">column &amp; boom<\/span><\/a><span data-preserver-spaces=\"true\">&nbsp;for approximate 1. positioning of the welding torch.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">A cross-slide assembly for precise control of the torch.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">System control unit.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Arc Control Unit for arc initiation, voltage and current detection.<\/span><\/li>\n\n\n\n<li><a class=\"editor-rtfLink\" href=\"http:\/\/www.westermans.com\/PowerSources.aspx\" target=\"_blank\" rel=\"noopener\"><span data-preserver-spaces=\"true\">Welding Power Source<\/span><\/a><span data-preserver-spaces=\"true\">: usually around 350Amp, 100% duty cycle<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Hotwire Power Supply, such as the PEC HWT-75 (75Amp, 100% duty cycle).<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Water cooler for cooling the welding torch.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Welding torches (for example Fronius HVATT, HST, SBT) in lengths from 750 &#8211; 1750mm.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Turntables and&nbsp;<\/span><a class=\"editor-rtfLink\" href=\"http:\/\/www.westermans.com\/WeldingPositioners.aspx\" target=\"_blank\" rel=\"noopener\"><span data-preserver-spaces=\"true\">welding positioners<\/span><\/a><span data-preserver-spaces=\"true\">, <\/span><span data-preserver-spaces=\"true\">typically up to 10,000kg capacity.<\/span><\/li>\n\n\n\n<li><span data-preserver-spaces=\"true\">Operator pendant controls.<\/span><\/li>\n<\/ol>\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<span class=\"embed-youtube\" style=\"text-align:center; display: block;\"><iframe loading=\"lazy\" class=\"youtube-player\" width=\"640\" height=\"360\" src=\"https:\/\/www.youtube.com\/embed\/5KP1Co8bDUA?version=3&#038;rel=1&#038;showsearch=0&#038;showinfo=1&#038;iv_load_policy=1&#038;fs=1&#038;hl=en-GB&#038;autohide=2&#038;wmode=transparent\" allowfullscreen=\"true\" style=\"border:0;\" sandbox=\"allow-scripts allow-same-origin allow-popups allow-presentation allow-popups-to-escape-sandbox\"><\/iframe><\/span>\n<\/div><\/figure>\n\n\n\n<p><strong><span data-preserver-spaces=\"true\">New Technologies: Rotary Welding Heads and Hot Wire Welding.<\/span><\/strong><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">For as long as arc welding has been around, the welder would either manually move his welding torch around the joint or surface he is welding, or mount it on a <a href=\"https:\/\/www.westermans.com\/blog\/what-is-the-purpose-of-a-welding-positioner\/\" title=\"How to benefit from using a welding positioner\">turntable <\/a>for mechanised rotation of the part.<\/span> <span data-preserver-spaces=\"true\">Oil &amp; Gas industry wellhead valves have become heavier (50 tons) and have more complex shaped bores that require the component to be mounted &#8216;off centre&#8217; to the table rotating axis. This results in accelerated wear of the supporting bearings and drive gears of the turntable.<\/span> <span data-preserver-spaces=\"true\">Centring a bore on a large block valve to the table centre is also time-consuming and a strenuous task for the operator.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">Faced with these ongoing issues with conventional cladding technology, a breakthrough was made in weld cladding technology by replacing the turntable altogether and rotating the torch instead of the component (which remains stationary). <\/span><span data-preserver-spaces=\"true\">The torch <\/span><span data-preserver-spaces=\"true\">is mounted<\/span><span data-preserver-spaces=\"true\"> on a weld head that rotates <\/span><span data-preserver-spaces=\"true\">which gives<\/span><span data-preserver-spaces=\"true\"> rise to the name &#8216;Rotary Head&#8217;.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">A new technology in the welding process for weld overlay and cladding is hot wire welding. Although invented many years ago, this technology never saw the light of day until recently.<\/span> <span data-preserver-spaces=\"true\">Hotwire welding and cladding was the subject of a one-day conference at the&nbsp;<a href=\"https:\/\/www.fabtechexpo.com\" target=\"_blank\" rel=\"noopener\" title=\"Find out more about the Fabtech &amp; AWS Expo in Chicago\">FabTech Int\u2019l and AWS Welding Show<\/a> in Chicago, with presentations on hot wire GTAW and hot wire plasma processes.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">Featuring the popular use of hot wire tig cladding of tube and piping for the offshore oil and gas industries. Plus hot wire GTA \u201cnarrow groove\u201d welding and its superior performance on titanium.<\/span> <span data-preserver-spaces=\"true\">Advantages are increased deposition rates and faster travel speeds.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">The hot wire tig process has increased in popularity over multiple groove welding, build-up and cladding operations. Commercially available and specialised hot wire equipment continues to promote the usage of the process for producing high-quality welds. Industries including nuclear, power generation, pressure vessels and offshore oil are common <\/span><span data-preserver-spaces=\"true\">areas of application<\/span><span data-preserver-spaces=\"true\">.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">Where&nbsp;a considerable amount of work is directed toward pressure vessel fabrication, hot wire gas tungsten arc welding is used extensively for the <a title=\"TWI explain more about narrow gap welding\" href=\"https:\/\/www.twi-global.com\/technical-knowledge\/faqs\/faq-what-is-narrow-gap-welding#:~:text=The%20advantages%20of%20the%20narrow,preparation%20is%20almost%20parallel%2Dsided.\">narrow gap welding<\/a> of nickel-based alloys. As well as build-ups, butterings, and cladding of high-strength low-alloy steel.<\/span><\/p>\n\n\n\n<p><span data-preserver-spaces=\"true\">If you&#8217;re an engineering company that undertakes overlay welding or weld cladding, have you thought about buying used equipment? Having supplied and purchased a range of Fronius, Welding Alloys, and TPS machines Worldwide, our client base includes the likes of <a href=\"https:\/\/www.wellboreintegrity.com\" target=\"_blank\" rel=\"noopener\" title=\"See Wellbore Integrity's website\">Wellbore Integrity Solutions<\/a>, <a href=\"https:\/\/srienergy.com\" target=\"_blank\" rel=\"noopener\" title=\"Find out more about SRI Energy\">SRI Energy<\/a>, and <a href=\"https:\/\/www.onesubsea.slb.com\" target=\"_blank\" rel=\"noopener\" title=\"Who are OneSubsea?\">OneSubsea<\/a>. Whether you&#8217;re looking to invest in another <a href=\"https:\/\/www.westermans.com\/claddingsystems.aspx\" title=\"See weld cladding and overlay machines for sale\">overlay welding machine<\/a>, or have a system surplus to requirements, <a href=\"https:\/\/www.westermans.com\/contactus.aspx\" title=\"Contact Westermans International\">get in touch<\/a> to find out more.<\/span><\/p>\n\n\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>In many industries, crucial parts are exposed to harsh, demanding conditions. Metal fabricators need a way to prolong the life of these parts, avoiding costly repairs and damage. That can often lead to catastrophic results in industries like construction, and &hellip; <a href=\"https:\/\/www.westermans.com\/blog\/description-of-the-weld-clad-overlay-process\/\">Continue reading <span class=\"meta-nav\">&rarr;<\/span><\/a><\/p>\n","protected":false},"author":1,"featured_media":8855,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"om_disable_all_campaigns":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[383,384,3],"tags":[256,324,392],"class_list":["post-7591","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-customer-resources-library","category-welding-cutting-processes-info","category-westermans-news","tag-cladding","tag-twi","tag-weld-overlay"],"aioseo_notices":[],"jetpack_featured_media_url":"https:\/\/www.westermans.com\/blog\/wp-content\/uploads\/2019\/01\/weldhero.jpg","jetpack_sharing_enabled":true,"jetpack_shortlink":"https:\/\/wp.me\/p2Ygth-1Yr","_links":{"self":[{"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/posts\/7591","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/comments?post=7591"}],"version-history":[{"count":17,"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/posts\/7591\/revisions"}],"predecessor-version":[{"id":11127,"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/posts\/7591\/revisions\/11127"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/media\/8855"}],"wp:attachment":[{"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/media?parent=7591"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/categories?post=7591"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.westermans.com\/blog\/wp-json\/wp\/v2\/tags?post=7591"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}