Weld overlay: a comprehensive guide to the process

Weld overlay: a comprehensive guide to the process

On this page we will delve into:


What is Weld Overlay

Weld overlay is a technique used to apply a layer of material onto the surface of a workpiece to enhance its resistance to corrosion, wear, or high temperatures. This process involves welding a protective metal layer onto a base material, improving its properties and extending its lifespan. The process can be performed using various welding techniques, depending on the desired outcome and specific application needs.


Why Do We Use Weld Overlay?

Weld overlay is utilized to extend the lifespan of heavily exposed parts by plating their surfaces with more durable materials.

This method is crucial for high-cost components designed for long-term use or for parts that cannot be entirely constructed from wear-resistant materials. It is frequently applied in the petrochemical and power generation sectors, particularly in pipe and manifold coating, and in the aerospace industry to strengthen engine parts.

M.E.G.A. offers a technology that merges two TIG arcs into one powerful arc. The preheated filler wire, heated by an additional current source, enhances efficiency and the fusion profile.

This process enables the adjustment of layer thickness between 1.5 and 3.5 mm, optimizing the amount of fused metal according to stringent criteria, leading to substantial material cost savings. Welding speeds can be optimized between 500 and 1000 mm/min, with deposition rates ranging from 2.5 to 6 kg/h, which is approximately three times higher than conventional Hot Wire TIG technology.


weld overlay


Benefits of Weld Overlay

Weld overlay offers numerous benefits that make it a valuable process in various industries.

  • Enhanced Durability: weld overlay significantly increases the lifespan of equipment by protecting against wear and corrosion. This added layer of protection ensures that components can withstand harsh operating conditions, reducing the likelihood of failures and extending the service intervals.

  • Cost-Effective: the cost-effectiveness of weld overlay lies in its ability to reduce the need for frequent replacements and maintenance. By enhancing the durability of components, companies can save on both material costs and labor associated with maintenance and repairs. This long-term savings can be substantial, especially in industries with high equipment usage.

  • Customization is a key advantage of weld overlay. It allows for specific material properties to be applied to different areas of a component, depending on the operational demands. For instance, surfaces exposed to high wear can be overlaid with wear-resistant materials, while areas prone to corrosion can be protected with corrosion-resistant alloys. This tailored approach ensures optimal performance and longevity.
  • Performance Improvement: weld overlay enhances the mechanical properties of the base material, making it more suitable for demanding applications. The overlayed material can provide superior hardness, toughness, and resistance to environmental factors, thereby improving the overall performance of the equipment. This enhancement is crucial for industries that operate under extreme conditions and require reliable performance from their machinery.


Industries and Applications

Weld overlay is utilized across various industries due to its ability to enhance the performance and longevity of components. In the oil and gas industry, it is commonly used for pipelines and drilling equipment, providing protection against corrosion and wear. Power generation facilities employ weld overlay in turbines and boilers to withstand high temperatures and harsh conditions.

The chemical processing industry benefits from weld overlay by applying it to tanks and reactors, enhancing their resistance to corrosive substances. In aerospace, weld overlay is used in jet engines and other high-performance components, ensuring they can endure extreme temperatures and stresses.


Material Often Used in Weld Overlay

The selection of materials for weld overlay depends on the specific requirements of the application. Stainless steel is a popular choice due to its corrosion resistance and strength. Inconel, a nickel-chromium-based super alloy, is ideal for high-temperature applications, offering excellent resistance to oxidation and corrosion.

Cobalt-based alloys are often used for wear-resistant surfaces, providing durability in harsh environments. Nickel alloys are chosen for their toughness and corrosion resistance, making them suitable for various demanding applications. These materials are selected to enhance the performance and lifespan of the base material, ensuring it meets the necessary operational standards.


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