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WELD OVERLAY TECHNOLOGY:

Weld overlay, also known as hard facing, is a critical technique for protecting industrial equipment from the severe abrasion and wear of harsh operating environments. At Rozen Steelworks, we specialize in delivering high-quality weld overlay solutions that extend the lifespan of your critical components and optimize the efficiency and safety of your operations.

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What is Weld Overlay?

Weld overlay involves applying a protective layer of specialized metal to the surface of a base material. This protective layer, or cladding, acts as a shield against abrasion, corrosion, and impact damage, significantly increasing the lifespan of your equipment.

The Weld Overlay Process:

Our skilled technicians meticulously execute the weld overlay process, ensuring superior quality and adherence to industry standards:

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  1. Preparation: The base material is carefully prepared by cleaning and potentially machining the surface to ensure optimal bonding with the weld overlay.

  2. Weld Overlay Application: We utilize advanced techniques, including automated weld overlay, to precisely apply the protective layer. Our robotic weld overlay equipment ensures consistent quality and efficiency.

  3. Finishing: After the weld overlay is applied, we may perform finishing operations like heat treatment or machining to achieve the desired dimensions and surface finish.

  4. Quality Control: Rigorous quality control inspections, including non-destructive testing (NDT), guarantee the integrity and performance of the weld overlay.

Benefits of Weld Overlay Protection:

  • Extended Equipment Lifespan: Weld overlay dramatically increases the resistance of components to wear and tear, extending their service life and reducing the need for frequent replacements.

  • Enhanced Performance: By protecting critical surfaces, weld overlay maintains equipment efficiency and prevents costly downtime caused by premature wear or corrosion.

  • Cost Savings: Investing in weld overlay protection can significantly reduce maintenance costs and extend the overall lifespan of your equipment, leading to substantial long-term savings.

  • Improved Safety: Weld overlay enhances the safety of your operations by preventing equipment failure and reducing the risk of accidents caused by wear and tear.

Rozen Steelworks: Your Weld Overlay Experts

Our state-of-the-art facility houses advanced robotic weld overlay equipment, including four-head straight machines and robotic bend equipment capable of handling complex 3D and 5D bends. We can simultaneously weld concentric and eccentric reducing pump spools, ensuring efficient and precise weld overlay application.

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We offer a wide range of weld overlay alloys to meet your specific needs, including:

  • Chromium carbide alloys

  • Tungsten carbide

  • Complex carbide

  • Stellite

  • Various stainless steel alloys for corrosion and abrasion resistance

Weld Overlay Applications:

Weld overlay provides exceptional protection for a variety of industrial applications:

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  • Hydro Transport Pipes: Protect pipes from extreme abrasion caused by slurry transport.

  • Tailings Lines: Extend the life of tailings lines in mining operations.

  • Mining Buckets: Reinforce mining buckets against impact and abrasive wear.

  • Cladded Plates for Mining Equipment: Manufacture wear-resistant components like chutes, hoppers, and wear liners.

  • Oil and Gas Industry: Safeguard pipelines and other components from corrosion.

  • Petrochemical Industry: Protect reactors, columns, and pipes from harsh chemicals.

  • Power Plant Equipment: Shield boiler tubes and components from high-temperature corrosion.

Discover the benefits of Rozen Steelworks' weld overlay expertise. Our Weld Overlay Procedures are designed to meet or exceed all industry specifications throughout Canada.

Contact us today to discuss your project requirements and let us provide you with customized weld overlay solutions that enhance the performance, lifespan, and safety of your critical equipment.

Pipe diameters of 6”- 60” can be delivered in 40-foot lengths. We offer 3D and 5D bends with weld overlay in pipe sizes between 24” to 60". â€‹â€‹

Chrome Carbide Overlay Testing includes but not limited to:

  1. Chemical Analysis: Cr >25%, C>3%, Carbide Volume Fraction (CVF) >35%

  2. Deposit Hardness > 510Hv10

  3. Overlay Surface Hardness > 510Hv10

  4. Overlay thickness: 8.0mm + 2.0mm/-0.0mm for double pass weld overlay

  5. Metallographic Examination, Primary carbides>35% volume, underbead cracking and Planar Cracking: crack length <30% of the bead width, as observed along the length of the weld coupon.

  6. Surface smoothness: +2.0mm/-0.0mm

  7. ASTM G65 Abrasion Test: <0.18g loss at 25% and 75% depth.

  8. AITF Rotary Impact Test: <3.0g after 3600 cycles ( 24minutes)

  9. AUT Automated UT <30% the max allowable % of underbead cracking/ disbondment

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