What is Weld Overlay?

What is Weld Overlay? - A Guide by Rozen Steelworks

Application of Weld Overlay inside a pipe spool.

You've probably heard the terms "cladding" and "overlay" when talking about welding. While they're similar, they're not quite the same. Both are used to improve the surface of a base metal, but they do it in slightly different ways. This guide from Rozen Steelworks will explain what weld overlay is, how it differs from cladding, and why it's so useful.

Cladding vs. Weld Overlay

To understand what weld overlay is, it helps to know how it compares to cladding:

• Cladding: This process uses either welding (fusion welding) or mechanical methods to add a layer to the base metal. Think of processes like roll bonding or powder metallurgy. Cladding is used to improve things like the metal's strength, temperature resistance, and resistance to corrosion, stress, and wear.

• Weld Overlay: This is a specific type of overlay. It uses welding (specifically, arc welding) to add a protective layer to the base metal. The main goal here is to protect the base metal from things like corrosion and to make it last longer.

  
  

So, while cladding is a broader term, weld overlay is a more specific welding process used for protection and longevity. Learn more about RSW's weld overlay services here.

Weld Overlay Techniques

There are several different welding techniques used for weld overlay, and the best choice depends on the job:

• Laser Welding: This is a precise and efficient method.

• SMAW (Shielded Metal Arc Welding): A common and more affordable option.

• MIG/TIG (Metal Inert Gas/Tungsten Inert Gas): Versatile methods that use a shielding gas.

• PTA (Plasma Transferred Arc): Used for complex, hard alloys.

• Submerged Arc Welding: The arc is hidden under a layer of flux.

  
  

Why Use Weld Overlay?

Weld overlay is a valuable technique because it increases the lifespan of components by protecting the metals from corrosion. This makes it useful in industries where pipelines, manifolds and other components are exposed to harsh conditions. These include slurries, sour gas, saline water, and other corrosive substances found in oil and gas exploration and processing. By extending the life of your equipment and pipes, you reduce the need for new materials and manufacturing, contributing to a more sustainable and resource-conscious operation, as well as cost-savings on materials. (To learn more about what we use weld overlay for click here.)

Industries That Use Weld Overlay

Weld overlay is used in various industries, including:

• Power generation

• Petrochemicals

• Mining

• Construction

Materials Used in Weld Overlay

Common materials used for weld overlay include:

• Stainless steel

• Chromium-based alloys

• Nickel-based alloys

  
  

FAQ: Weld Overlay

1. What is weld overlay used for?

Weld overlay is used to add a protective layer to a base metal, primarily to improve corrosion resistance and extend the lifespan of components.

2. How is weld overlay different from cladding?

Cladding is a broader term that includes weld overlay. Cladding involves depositing a surface layer using fusion welding or mechanical processes, while weld overlay specifically uses welding (arc welding processes) to apply a protective layer.

3. What are the different types of weld overlay?

The main types of weld overlay include laser welding, SMAW (Shielded Metal Arc Welding), MIG/TIG (Metal Inert Gas/Tungsten Inert Gas) welding, PTA (Plasma Transferred Arc) welding, and submerged arc welding.

FAQ: Rozen Steelworks

1. Where are you located?

We are located just outside of Edmonton, in Acheson Alberta Canada.

2. What services do you offer?

We offer a range of services including tailings management solutions, pipe fabrication, barges and floating assets, structural steel fabrication, and weld overlay.

3. What sets Rozen Steelworks apart?

We leverage automation and advanced technology to enhance efficiency and deliver exceptional results. We are a proud Canadian company.