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Weld overlay is a specialized cladding technique used to deposit a layer of corrosion (or wear) resistant material onto the surface of base components such as pipes, fittings, forgings, and flanges. Instead of manufacturing the entire component from expensive alloys, weld overlay allows a strong base material (like carbon or low-alloy steel) to be reinforced with a protective layer of INCONEL the majority of the times. This approach ensures long-term reliability in demanding environments while optimizing costs.
Weld overlay involves fully automated welding processes where filler material is melted and bonded onto the base metal. M.E.G.A. employs advanced technologies such as TIG hot wire processes (including the proprietary TIGer system).This method ensures high-quality welds, low dilution rates, and excellent deposition efficiency. The TIGer processuses dual tungsten electrodes forming a single arc, delivering higher deposition rates, lower arc pressure, and superior metallurgical bonding.
Horizontal cladding is performed using longitudinal twin TIGer technology, allowing two layers to be applied in a single run. CNC-controlled systems with integrated pre-heating and cooling devices guarantee consistent quality along the internal or external surfaces of long products such as pipes. Real-time monitoring through dual cameras ensures precision during welding operations.
Vertical cladding is achieved with SPXCNC TIGer equipment, which uses an endless rotating head. This design allows the workpiece to remain stationary on the ground while the welding torch rotates around it. The innovation makes it possible to clad even highly asymmetrical components. The equipment can handle internal diameters as small as 38 mm and product lengths up to 2,000 mm, offering flexibility across a wide range of applications.
Weld overlay is primarily used to extend the life of components exposed to corrosive, high-temperature, or abrasive environments. Instead of replacing entire pipeline elements, weld overlay restores or enhances the performance of existing components. It is especially valuable in oil & gas, petrochemical, offshore, subsea, power generation, and nuclear applications, where equipment reliability is critical to safety and efficiency.
The main benefits of weld overlay include:
Applications range from cladded buckle arrestors and barred tees for subsea installations to large-diameter pipes and pressure vessel components used in power plants and refineries.
M.E.G.A. provides weld overlay with a wide range of Corrosion Resistant Alloys (CRA), including:
The base materials typically include carbon-manganese steels, low-alloy steels, high-alloy steels, martensitic and ferritic stainless steels. This wide material compatibility ensures weld overlay can be adapted to virtually any industrial application.
At M.E.G.A., we combine advanced weld overlay technology with decades of expertise to deliver safe, reliable, and cost-effective solutions for the most demanding industries, such as fittings for oil & gas industry.
Contact our technical team today to discuss your project requirements and discover how weld overlay can extend the life and performance of your components.