GMAW Weld Overlay

Gas Metal Arc Welding (GMAW) Overlay Cladding – The Ultimate FAQ Guide

GMAW weld overlay is one of the more common types in performing weld overlay. Because of its simplicity and effectiveness, it’s one of the techniques loved by many industrial companies.

In this guide, we will be walking you through the GMAW weld overlay process. We’ll talk about everything you need to know about it; what it is, how it can help you with your business, as well as the machines needed to complete the work.

What is GMAW?

It’s a short term for Gas Metal Arc Welding.

It describes the process where an electrode is fed through the torch at a steady and controlled rate.

Simultaneously, you ought to apply shielding gas to the site or point of welding to avoid weakening the weld.

Is GMAW the Same as MIG?

MIG or Metal Inert Gas welding is actually a subset of GMAW.

The GMAW process can have different options for shielding. They are:

• Using a Flux-Cored Wire
• Gas Flowing Through the Torch

In MIG, on the other hand, it specifies the usage of inert gas (usually helium and argon). So, you can say that they’re the same in terms of process and the foundation.

However, they’re different in terms of the shielding procedure and selection.

What are GMAW Welding Machines?

GMAW welding machines are the equipment you can use to perform the GMAW process.

In GMAW, you can choose from the four (4) different methods of metal transfer. They are:

• Spray
• Pulsed Spray
• Globular
• Short-Circuiting

What Does Weld Overlay Mean?

Weld overlay is the deposition of one or more metals to a specific part or product.

The overall goal of weld overlay is to improve desirable properties of the base product. Moreover, it can also be used to restore the shape and the dimensions of the component.

Is GMAW Cladding Different From GMAW Weld Overlay?

Cladding and weld overlay are terms that are usually interchanged. They’re processes that are almost similar, but deep down, they’re different.

GMAW cladding is a GMAW process that deposits material into the surface of a workpiece.

The goal is to coat the component to make it resistant against wear, corrosion, and abrasion.

GMAW weld overlay is a GMAW process that deposits material into the workpiece.

The goal is either to improve its properties or to restore its form, shape, or dimensions.

GMAW vs. FCAW Welding?

GMAW is a process that utilizes a solid wire electrode for its filler metal.

FCAW is short for Flux-Cored Arc Welding. It is a process that has materials in the core that when burnt, produces shielding and fluxing agents.

What’s different between them is their consumables. In FCAW you use a flux-cored wire, which is what releases the shielding agent.

In GMAW, however, you use a solid consumable wire electrode for it.

GMAW vs. GTAW Welding?

GTAW is a term short for Gas Tungsten Arc Welding.

The main difference that it has with GMAW is that it uses a non-consumable tungsten electrode; whereas GMAW uses a consumable wire electrode.

You can perform them in the same way, you just have a different electrode to use.

What is GMAW Cladding?

GMAW cladding uses the GMAW method to deposit materials to a surface or a workpiece.

The goal is to create materials that are better, stronger, and more durable; materials that are:

• Corrosion-Resistant
• Higher Impact Tolerance
• Higher Temperature Tolerance
• Abrasion-Resistant
• Wear-Resistant
• And So On

Benefits of GMAW Overlay Cladding?

In comparison to other welding techniques, GMAW cladding can give you the following benefits:

• Lower fumes, which creates a better sight of the project
• Can be used for a wide range of alloys and metals
• Does not require operator to be highly skilled
• Higher productivity because it can be fully automatic
• Has higher electrode efficiencies

These are just some of the benefits that the GMAW weld overlay process can give you.

Where Can a GMAW Weld Overlay Process be Best Applied To?

The general application of GMAW weld overlay would be in the following sectors:

• Chemical Plant Industry
• Paper Industries
• Naval Equipment Industry
• Power Plant Industry
• Oil & Gas Industry

So, if you are engaged in any of these sectors, you can benefit well from it. You will have no doubts about it.

What is a GMAW Weld Overlay For?

It’s the same as why you would want to get a weld overlay – to improve properties.

What separates it from the rest would be the ease of how it’s operated and the availability.

What Materials Can You Weld With GMAW Weld Overlay?

All of the most important metals can be welded using the GMAW weld overlay process.

Here are some of the things included in the list:

• Titanium
• Nickel Alloys
• Copper
• Stainless Steel
• Aluminum Steel
• And Many More

TIP: One BIG advantage that GMAW has is its ability to weld many alloys and metals. It’s flexible, versatile, and it’s not that demanding.

Does GMAW Weld Overlay Produce Slag?

GMAW uses a metal electrode for the shielding. Flux is one of the main agents that create slag.

But since you wouldn’t be using flux in GMAW, you can expect no slag.

What is Inconel?

Simply put, Inconel is a generalized term for a group or a family of super alloys.

It’s called Inconel because it is a trademarked term by the Special Metals Corp. The different alloys’ names are based off of their resistance, ductility, temperature, and so on.

Where Do You Use Inconel?

Because of its high corrosion resistance capacity, it’s used in many different applications. Inconel is deemed as the perfect material you can use for extreme chemical-reactive environments.

Some of the most common industries that use Inconel include:

• Oil & Gas Industry
• Nuclear Industry
• Aerospace and Marine Industry
• Chemical Reaction Industry
• And Many More

Keep in mind that Inconel is similar to other corrosion-resistant material; they’re just more extremely powerful and have more properties than the regular alloys.

Inconel vs. Stainless Steel

Both are unique and useful in their own way, but they’re used in different manners.

Inconel is a material that you want to use if you’ll be engaging in high temperatures, with more chemical reactivity. Because of its extreme resistance to corrosion, it’ll be useful in those fields.

Stainless Steel, on the other hand, is something you can use if you need a strong part in more normal temperatures. It’s also resistant to corrosion but when exposed to high temps, problems could arise.

Also, Inconel is far more expensive than Stainless Steel. It’s also often used in higher-temperature situations; whereas Stainless Steel is perfect for harder impact cases.

What is Overlay in Welding?

It’s the process of depositing metals to a parent metal with the goal of improving its properties.

Oftentimes, its main purpose is to restore or to rebuild the structure of the component.

What is Inconel Overlay?

Inconel overlay is the procedure of depositing super alloys to surfaces or workpieces.

You can perform Inconel overlay if you want to reinforce and develop equipment that would be:

• Exposed to high temperatures
• Under a lot of chemical pressure

Best Welding Procedure For Inconel Overlay

The best procedure would depend on the project that you need done.

Moreover, you can select any of the welding procedures available.

Whatever result you need would be the basis of what the best welding procedure is.

What is Inconel Cladding?

Inconel cladding is the process of enhancing the surface of a part or component.

The purpose is to deposit highly corrosive-resistant material to parts and components, with the goal of keeping it free from corrosion and oxidation.

Can Inconel Rust?

All Inconel alloys have high levels of oxidation and corrosion resistance. There’s little evidence that support it being rusted or corroded.

However, if you allow Inconel to be under extreme temperatures for long periods of time; the most resistant might also break off.

What’s the Difference Between Inconel 625 and Inconel 825?

Other than the number, the major difference between them involves the Nickel content. Nevertheless, here are their differences:

Nickel Content

Inconel 625 is approximately made up of about 58% Nickel; while Inconel 825 contains just around 36 % to 48%.

Melting Point

Another difference is their melting point. Inconel 625 melts at around 1350 degrees Celsius. Inconel 825, on the other hand, melts at around 1400 degrees Celsius.

Inconel 625 is part of the Inconel group that contains high amounts of Nickel. 825, however, contains moderate amounts of it.

There are other differences between them that point towards the utilization and the use of each of the material.

What Makes Inconel Corrosion-Resistant?

Inconel has been designed to be protective of the material it envelops.

In fact, when it reaches extreme temperatures, it forms and spews a thick layer of oxide.

This protects the part or the surface from corrosion and other attacks that might occur.

What is an Inconel Clad Pipe?

An Inconel clad pipe is a regular steel pipe is coated and fused with Inconel material.

Due to this, it’ll be less susceptible to corrosion and oxidation. Furthermore, it would adapt abundant levels of Nickel form the Inconel material.

Where Can You Use Inconel Overlay Pipes?

Inconel overlay pipes are perfect for environments and situations that have extreme temperature and chances of oxidation.

These are perfect for the Oil and Gas Industry, Chemical Projects, and the like.

Is Inconel Cladding and Inconel Overlay the Same?

A lot of times, they’re distinguished incorrectly because of the same processes.

Cladding is the process of depositing material through a surface with the goal of making it:

• Corrosion resistant
• Abrasion resistant
• Wear Resistant
• Stronger than what it is

Overlay is the process of improving and enhancing the properties of parts or components.

The process is most often used in varying conditions and instances such as restoring the shape or dimensions, preventing further wear, and the like.

Where You Can Get GMAW Weld Overlay Service?

There wouldn’t be a shortage of companies that can help you with a GMAW weld overlay.

In fact, many have already adapted to it. However, if you’re looking for the best and the highest quality, you can work with us here at Waldun.

Waldun has been the leading GMAW weld overlay company in China. Amassing thousands of clients who trust us, you can’t go wrong.

The next project where you’ll need the GMAW weld overlay cladding process, work with us! Experience high quality procedures without spending a fortune for it!