Weld Overlay – The Ultimate FAQ Guide

Most machines and equipment of industrial companies are exposed to corrosion, abrasion, wear, and the like.

That being said, these machineries need a bit of tweaking to last longer.

There are many procedures you can do to strengthen your equipment, but what’s the best one? All experts have their take, but a wide majority considers weld overlay as the best.

What is Weld Overlay?

Weld Overlay Image

It is the process of joining one or more metals together via welding. You would deposit abrasion and corrosive resistant materials onto the parent workpiece.

What is the Purpose of a Weld Overlay?

The purpose of a weld overlay is to improve properties of the surface or the base metal.

Weld Overlay Purpose

Since you’re to apply wear resistant materials to the workpiece, it strengthens the base. However, you can also consider it as a process to restore equipment or a component.

How Do You Define Hardfacing?

Hardfacing is the metalworking process where the harder material is placed onto the base metal.

Hardfacing Sample

It’s called “hardfacing” because you put the tougher material onto the base.

You enhance the component completely to strengthen it against abrasion, erosion, corrosion, etc.

What is Cladding?

Cladding is a welding procedure where you put welded metal onto the surface.

Cladding Sample

You would apply a dissimilar material over a surface to serve as a protective layer.

It’s referred to as “cladding” because you’ll use a different material than the base metal.

Where Can You Use Cladding?

Cladding Uses

Cladding is used to cover a surface of equipment, parts, or a machine. You can use cladding if you are:

  • Trying to improve a part or a component of a machinery
  • Looking to make a part wear resistant or abrasion resistant; and
  • When you’re looking to make a part resistant to corrosion

Weld Overlay vs. Cladding

Weld overlay is a welding process. It’s a process where you apply wear-resistant materials onto the parent component.

Frequently, the material would have the same properties applied to the parent surface.

The goal of weld overlay is ultimately to improve the properties of the base metal.

Cladding is a process where you would apply a different, tougher material than the base metal or surface.

Cladding’s main purpose is to act as a protective cover to the base metal.

What is Weld Overlay Cladding?

Weld Overlay Cladding Sample
Weld overlay cladding is the procedure of depositing thin layer of materials on components.

What is Pipe Cladding?

Pipe cladding is the process of bonding cladding material and a pipe.

Pipe Cladding Example

You can do this type of cladding using welding or an eruptive bonding procedure.

Are There Different Methods of Weld Overlay?

There are many different methods of weld overlay.

MIG Welding Photo

However, the main and the most important methods include:

  • C02 Welding
  • Shielded Metal Arc Welding
  • Metal Inert Gas (MIG) Welding
  • Plasma Transferred Arc (PTA) Welding
  • Submerged Arc Welding
  • Tungsten Inert Gas (TIG) Welding

Where Can You Apply Weld Overlay?

Weld Overlay Application

You can use weld overlay to a wide range of industries such as:

  • Oil Industry
  • Gas Industry
  • Manufacturing Industry
  • And Many More

However, it’s mostly applied to parts and components usually exposed to wear, abrasion, and corrosion.

Some of the most common types of equipment include:

  • Excavation Equipment
  • Pipelines and Fittings
  • Valves and Vessels
  • Mining Equipment

What is Bolting?

Bolting, simply is the process of joining parts and components using bolts and screws alone.

Controlled Bolting Sample

As opposed to welding, you don’t need to melt the steel to put two pieces of surfaces together.

Is Welding Stronger Than Bolting?

Welding is better and stronger than bolting. Welding uses intense heat, chemical reactions, and compounds to put steel together.

Welding vs. Bolting

Bolting needs fasteners and its structural elements to hold pieces together.

Even if you find bolting easier, you would want to consider welding because of its reliability.

Is Buttering the Same as Hardfacing?

Hardfacing and buttering are two different processes.

Buttering is a surfacing variation of depositing a weld layer on the metal or the surface.

The purpose of buttering is to gain compatible weld metal you need to complete the weld.

Hardfacing is the deposition of tougher, harder, and stronger material to a base or the parent surface.

Hardfacing’s goal is to improve a component, making it resistant to many different types of wear such as:

  • Abrasion
  • Erosion
  • Impact
  • Heat
  • Corrosion

What is Overlap in Welding?

Overlap is something that happens when the welded part flows out to the surface of the base material.

Overlap Sample

What are Crater Cracks in Welding?

Crater cracks in welding are inconsistencies and irregularities in the welding process.

Crater Cracks in Welding
You will notice a crater crack easily because it will look cracked, broken, and inconsistent.

What Causes Crater Cracks in Welding?

The main causes of a crater crack are inconsistency and sudden changes.

Crater Crack Sample 2

If you’re welding and you stop before finishing a weld joint, it will leave a wide crater at the end.

What are the Four (4) Main Welding Positions?

Flat Welding Position

The four (4) main welding positions include:

  • Horizontal Position Weld
  • Vertical Position Weld
  • Flat Position Weld
  • Overhead Position Weld

What is the Weld Overlay Procedure?

The weld overlay process is pretty simple:

  1. Select the weld metal to be put on the surface
  2. Mount the workpiece on a flat surface
  3. Set the welding torch stationary and uniform
  4. Check for irregularities and inconsistencies

What is Metal Overlay?

Weld metal overlay Is a process of fusing one or more metals together. You can achieve it by welding a thin piece of alloy (nickel-base) or steel to a part or a workpiece.

Metal overlay is considered as a cost-effective way of enhancing and developing properties.

What is Meant by Weld Overlay?

It is known and defined as a steel or metal deposition process.

Metal Overlay

Weld overlay is a process that uses welding and it aims to deposit material to base or parent metals.

Primary Types of Metal Overlaying

There are different types of metal overlay.

Types of Metal Overlaying

You can separate and categorize metal overlaying into four (4) different types:

Hardfacing Material

This process or type of metal overlay is used to decrease abrasion, impact, wear, and other damages to the surface of a part or a component.

Buttering Alloys

Buttering is the process of welding dissimilar metals to a surface. You would want to do it if you need to suffice metallurgical conditions and considerations.

Buildup Alloys

This process is the adding of metal or alloy to a base metal. However, the purpose is not to improve its capacities. Instead, it is to restore it; to make it look like what it was originally.

Weld Cladding

Weld cladding is a metal overlay process that adds a thick layer to a surface. Usually, it uses a carbon steel base or low alloy material for the purpose of increasing its resistance to corrosion.

These are the primary types of metal overlay that you can perform, depending on your goal.

Weld Overlay vs. Cladding: What’s the Difference?

Many people, even you, have the misconception that both processes are the same; but they’re not.

Weld Cladding

Cladding is a process you would want to do if you want to add protective layer to your parts. Furthermore, cladding can be done by welding or by mechanical methods.

Weld overlay is what you need to do if you want to enhance properties of parts or components. When it comes to application, weld overlay can only be done via welding fusion.

What is Meant by Metal Cladding in Welding?

Metal Cladding in Welding

It is the process of protecting a metal by forming a second layer of metal to its surface or core. If you want to improve the resistance of your parts, cladding is the way to go.

What is a Cladding Material?

Clad material is what you use in metal overlay or cladding to protect and improve resistance.

Cladding Materials

They’re the components added to the base metal for the results you want to see.

What is the Purpose of Metal Overlay?

You can get a metal overlay procedure for many different reasons.

Purpose of Metal Overlay

The most common ones that people have include:

  • For the restoration of dimensions of your machines/equipment
  • To improve its desirable properties and characteristics
  • For the purpose of making it wear or corrosion resistant
  • To further its lifespan and functionality

Basically, metal overlay’s main use is to improve a part or a component of your machines. Whether in a physical or in a chemical sense, its goal is to enhance and further develop a part or a component’s properties.

What is a Corrosion Resistant Metal Overlay?

It is a process of performing a metal overlay using corrosion resistant materials and compounds.

Heap of shiny metal steel pipes with selective focus effect

You would want to do a corrosion resistant metal overlay procedure if you want to enhance or reinforce the corrosion resistance of a certain part of component of a machine.

Metal Overlay Service Price

Metal Overlay Service

The prices and rates for a metal overlay service would depend on certain factors, these factors include:

  • The type of the material to be welded
  • Surface and the base metal
  • Shape and size of the material

The best way to know the price for the service would be to ask your contractor.

Metal Overlay Machines Price

Roughly, the prices for metal overlay machines and equipment are above $3,500; it can even go as high as $12,000. You can know the exact amount, by asking the manufacturer.

This way, you can also find out about other products that can help you with whatever your projects are.

What is Metal Cladding Restoration?

Metal Cladding Restoration

Metal cladding restoration is a restoration process. It uses the metal cladding procedure to restore the dimensions of a part by saving it from rust, corrosion, or other types of wear.

Is Weld Overlay and Cladding the Same?

Weld overlay and cladding are two different processes. However, they’re most often interchanged and many people think that they’re the same.

Weld Overlay

Weld overlay is the process of depositing minerals into a surface.

Oftentimes, its purpose is to enhance and developed properties or traits of an already finished product; it uses deposits that have similar characteristics with the substrate.

Cladding, on the other hand, is the process of applying minerals into an unfinished product.

The goal of cladding is to deposit a layer of protective material onto the surface of the workpiece. In cladding, dissimilar alloys can be utilized.

What’s the Difference Between Weld Overlay and Cladding in Terms of Processes?

There are many similarities between them, that’s why they’re always seen as one process.

Cladding Process

But, one distinct thing that separates them would be their process.

Cladding is a process that can utilize either fusion or mechanical methods. Either way, the goal remains the same.

Weld Overlay, on the other hand, only uses fusion method without using any mechanical applications.

Weld Overlay Process

What is Weld Overlay Cladding?

Weld overlay cladding is a process formed from combining welding overlay and cladding.

Weld Overlay Cladding

It’s a process that deposits reinforced material to a surface or a workpiece, finished or unfinished. More so, it’s used to weld and fuse dissimilar types of alloys.

The goals of weld overlay cladding are to:

  • Reinforce the workpiece or the material more efficiently by improving its properties
  • Be able to deposit corrosion, abrasion, and wear resistant minerals to the surface
  • Extend and prolong the life of equipment, machines, parts, and components

What are the Applications For Weld Overlay Cladding?

You can use weld overlay cladding to help improve and enhance parts and components.

Weld Overlay Cladding Applications

The most common applications for it include:

  • Pipes, Tubing, & Fittings
  • Valves
  • Heavy-Impact Equipment
  • Corrosion-Prone Machines and Components
  • And Many More

There are many industries that utilize weld overlay cladding. Oftentimes, they’re industries that are always subject to abrasion, corrosion, wear, etc.

What Benefits Can Weld Overlay Cladding Get You?

The advantages that weld clad overlay can get you would be the following:

Cost Savings

Because you can improve your part or component, there’ll be no need to buy new ones.

It might be quite a lucrative process, but it’s cheaper than purchasing new equipment.

Longer Life of Materials and Equipment

Enhancing its properties and improving physical and chemical resistance, you prolong your equipment’s lives.

Them having longer lives mean that you’ll get more savings and less stress about machines.

Less Maintenance Requirement

By undergoing a weld clad overlay process, you’ll not be subject to maintain them on a regular basis. Instead, you can leave them and check on them from time to time.

What are Weld Overlay Cladding Machines?

These are the equipment or the machines that can help you with the weld clad overlay process.

Weld Overlay Cladding Machines

They’re heavy-duty machines that are stationary and that can assist you with your project.

What is a Weld Overlay Flange?

Weld Overlay Flange

Also known as cladding flange, it’s a process of using weld overlay cladding procedure to build up an alloy that contains a much more corrosion resistant properties to flanges.

What is the Most Popular Method for Weld Overlay Cladding?

Out of the many different methods for Weld Overlay Cladding, the SMAW is the most popular.

SMAW

SMAW, short for Shielded Metal Arc Welding, is a welding process that uses manual metal arc welding.

How is Weld Overlay Cladding Done?

The process of weld overlay cladding is done by joining two dissimilar metals together.

Weld Overlay Cladding Process

Imagine a large pipe that is made out of a cheap alloy. In order for it not to oxidize while it’s being used, you need to perform weld overlay cladding.

This adds up a coating of stainless steel to the cheap alloy, making it resistant to corrosion, rust, abrasion, and other types of wear.

Who Can Help You With a Weld Overlay?

There are a lot of companies that you can ask help from with your weld overlay requirement.

But you can consider us here at Waldun as your go-to option. We have state-of-the-art welding machineries and equipment.

Don’t worry about minimum orders, we will supply based on your business’s demands.

How Can You Get a Weld Overlay Service?

If you have a company in mind, you can contact them about your request of a weld overlay.

You can send them an email, dial their hotline, or reach their customer service for assistance.

Also you can contact us now.

Which Weld Overlay Cladding Companies Can You Trust?

There are a multitude of companies that offer weld overlay cladding services. In fact, there are also that sell weld overlay cladding machines.

You can search the market for those that are on the same page as you. But, if you want to work with the best, work with us here at Waldun – the leading brand for the weld overlay cladding process and for weld overlay cladding equipment.

Where Can You Purchase Weld Overlay Cladding Machines?

While there are a lot of companies that offer these types of equipment; you can actually get a wide variety of weld overlay cladding machines with us here at Waldun.

Whatever type of machine you need, we’re sure that we can get it for you.

What are the Advantages of Our Weld Overlay Cladding Machines?

Why choose us to be your supplier for your weld overlay cladding machines?

Other than the fact that we offer a wide range of options, here are some other benefits and advantages of purchasing our weld overlay cladding equipment:

  • We have CNC-powered and controlled machines
  • You can ask us for a custom built machine and a custom built weld overlay cladding service
  • It contains high automation
  • Simple and easy to operate
  • And many more

You will never find another company the provides the same types and kinds of weld overlay machines like what we offer here at Waldun.

Buying Guide For Weld Overlay and Welding Overlay Machines

Are most of your equipment already subject to wear, abrasion and corrosion? Have you been looking for a solution for the fast wear of your parts and components?

If you’re too busy thinking about a solution, worry not – that’s what welding overlay is for.

I know you can’t be too knowledgeable about it. This is why we made this guide for purchasing welding overlay and welding overlay equipment.

What We Will Cover?

This guide will discuss everything you need to know about welding overlay and equipment.

From its uses and advantages, why you need it, what you need to look for, and so on.

What is Weld Overlay?

Weld overlay is the process of fusing or depositing metallic components to a base metal.

What is Weld Overlay

Oftentimes, the deposited material would have the same characteristics as the base metal.

The goal of welding overlay is to improve desirable properties of the workpiece. It can be for any or all of these reasons:

  • Corrosion Resistance
  • Abrasion Resistance
  • Wear Resistance
  • Erosion Resistance
  • Restoration of Shape and Dimensions

What are Welding Overlay Machines?

They are the machines or the equipment used to perform welding overlay.

Welding Overlay Machines

You can choose form the many types of welding overlay machines such as:

  • Plasma Hardfacing Machinery
  • Laser Cladding Equipment
  • Flux-Cored Arc Welding (FCAW) Machines
  • Gas Metal Arc Welding (GMAW) Machines
  • And Many More

Where Can You Use Welding Overlay Machines?

Welding Overlay Machines Application

You can choose to use welding overlay equipment for a ton of industries. It can be for the oil and gas industry, the mining industry, the construction industry, plumbing industry; the list goes on.

The most common applications for it, though, include:

  • Pipes
  • Fittings
  • Vessels
  • Surface of Equipment
  • Valves
  • And So On

Why Do You Need Weld Overlay?

Weld overlay is a process that can extend the lifespan of your equipment.

Do You Need Welding Overlay_

For instance, you can perform a weld overlay to pipes in the oil and gas industry. What this does is it keeps the pipes from being swallowed by rust, corrosion, and abrasion. Your pipes would:

  • Last longer while in use
  • Have higher tolerance to impact and temperature
  • Be less likely to be corroded

Do You Need Welding Overlay Machines?

Yes – if you’re constantly worrying about the safety and the longevity of your equipment.

Do You Need Welding Overlay Machines_

Having welding overlay machines can guarantee that they’ll last longer; and they will be more effective even if you overuse them.

Things to Consider When Buying Welding Overlay Machines

Welding Overlay Machine Sample

Effectiveness

You need to look for machines that are effective in certain stress and temperature situations.

There are some equipment not applicable in high temperatures. So, if you would need to perform welding overlay in such a location, you need to consider if it’s going to be effective.

Speed and Accuracy

In choosing a machine, you need to be wary of its welding speed.

Typically, it should be somewhere between 200 – 2,000mm per minute to achieve fast results. However, if it doesn’t fit the budget, you can settle to around 150 to 1,500mm/minute.

Size

We’re not just talking about the size of the machine itself, but also the size of the worktable.

Ideally speaking, the minimum would be around 1,000×2,000mm. If you want to go big and if you want to achieve results faster, go for equipment within the ranges of 1,500 to 2,000x 3,000 to 3,500mm.

Factors to Look at When Choosing a Company to Work With

Do you need a hand in the welding overlay that you need but don’t know how to choose who to work with?

Welding Overlay Company

Worry not! Here’s how you can choose a company to work with.

Experience in the Industry

Experience is important in the welding industry. Apart from better and higher quality results, they’ll be able to juggle their time better.

If you were to choose a company, go with a company that has relevant experience in the industry. Not only will you be given the assurance of achieving results, but also the removal of stress during the project.

Proof of Work and Projects

Who would want to work with a company that can’t provide proof or samples of their work?

When you are to inquire about a company’s welding overlay procedure, you can ask for a sample or a demo to see if they’re up to your standard.

Time of Delivery

Last but definitely not the least would be their commitment. Ask yourself these questions and see if the company you’re looking at can comply:

  • How do I want the projects to be delivered?
  • Would they be providing updates from time to time?
  • How fast can their machines work?

Companies might not have all of it. So, if you were to choose, it will depend on your needs.

Do you need fast delivery? Do you care more about the quality of work? Do you want to see proofs of all the projects a company has accomplished?

Work With Us!

If you want supreme and high-quality service; and if you’re also looking to purchase quality welding overlay machines and equipment, work with us here at Waldun!

Waldun has been the industry’s name since 2005 and we never failed to provide our clients with the quality of the products and the services they need.

We excel most in our welding overlay procedure; this is one of the first processes we’ve mastered.

Why Choose Waldun?

  • We have more than a decade of experience in the industry
  • All our welders, staff, and our personnel are experienced and knowledgeable
  • Our welding overlay equipment are all of a high quality

Features of Our Welding Overlay Equipment

All our equipment and machineries are all refined and maintained on a regular basis.

In fact, here are some of its most notable and the most recognized features:

  • It has a breakpoint welding function
  • Water cooling effect is fast and reliable
  • Small chances of deformation in every project
  • Highly automated – IPC controlled
  • They’re CNC-capable and automated

Look no further and work with the best! You will never regret your decision of working with us!

Weld Overlay | Welding Machine & Solution

You are always striving to find a weld overlay solution to improve the durability of your facilities, and advanced welds provide a highly suitable repair method.

With WALDUN high level of expertise, you can get the related weld overlay solution required to achieve unparalleled high quality weld seam pads.

With Waldun wide range of options for individual metal production,you can get a wide range of weld overlay services.

From high-quality, cost-effective welding services to high-quality welding coatings. Learn more about our welding overlay, other welding services and different types of weld overlay we offer.

laser cladding applications

A specially developed and automated weld overlay system is designed to restore and protect critical industrial processing plants through advanced welding technology.

WALDUN has developed a welding system specifically designed for industrial applications to meet the needs of high-quality industrial and industrial welding equipment.

The welding overlay process provides protection by using special manufacturing in hostile environments.

A welding process, a specialized welding system for industrial use, was developed by WALDUN, which was specially designed for the requirements of industrial welding applications, especially in the field of welding and metal production.

Corrosion – Resistant weld seam coatings are often used to improve components corrosion resistance made of materials that are otherwise susceptible to corrosion.

Corrosive – Weld seam pads are commonly used in the automotive, aerospace and other industrial applications, as they improve the reliability and durability of components made from otherwise corroded or corrosion-prone materials.

Roughly speaking, it can be used on a variety of materials such as steel, aluminum, copper, glass, stainless steel and many others.

Metal overlay or weld seam superposition is a similar process that is often used in several metal working processes.

When two or more metal-specific properties are applied to a base metal, we speak of welding coatings or overlay.

The weld overlap can be achieved by the following methods: arc welding, plasma arc welding to shield the metal welding, self-shielding – coring of the wire and arcs to shield the weld seam support and other industrial applications.

Let’s review each of them in details.

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Weld Overlay Machines

Robotic Hardfacing

Plasma Hardfacing: Plasma powder surfacing uses a plasma arc as a heat source. After the plasma beam leaves, it cools down and forms a high-performance alloy layer. Thus the surface of the part is strengthened and hardened.

Two heads hardfacing equipment

FCAW Welding Hardfacing is a kind of welding method. It produce self-protective gas after the flux cored and the welded parts produce arc. The welding wire is fused to a flat plate or a roller at high temperature.

1000W-6000W Laser cladding machine

Using a high-energy-density laser beam to melt with the thin layer on the surface of the substrate. The coating forms a cladding layer. The treatment can significantly increase the hardness and wear resistance of the surface and extend the parts’ service life.

Customers & Partners

 

WALDUN Weld Overlay Videos

Pipe Weld Overlay Video

Our advantages:

  • With our incorporation of China’s mechanical industry supply chain, which makes manufacturing expenses quite low.
  • We make use of famous international brands for our electrical and mechanical parts.
  • We produce a reinforced bed structure, annealing treatment for welding with our equipment. Hence, we are more knowledgeable about the manufacturing of welding overlaymachine
  • We ensure to test the machine before delivery to our customers strictly.
  • We also provide one year warranty, without any additional payment for installation and commissioning.
  • Our company adheres to export standard for the packing without compromising.
  • Provisions can be made for relevant wear-resistant welding technology transfer.

Case Study: TECKNOWELD OVERALL SOLUTION

TecknoWeld is a globally company acknowledged as the leader in providing state-of-the-art and quality wear products. READ MORE ABOUT How WALDUN Helped.

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