Poyyara Consultants

STRIP CLADDING
By
KAMAL KISHOR
Poyyara Consultants
CLADDING BY WELDING
What is Cladding by Welding?
Corrosive Surface of CS or LAS is
Cladded with Corrosion Resistant Weld
Metal ( SS, Monel, Inconel,
Cupronickel, Nickel, Brass,
Bronze) by Fusion welding Process
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CLADDING BY WELDING
Base Material: SA387 Gr11 Cl2
Surface with SS347 weld layers
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WELDING PROCESSES FOR
CLADDING

GTAW/SMAW/FCAW/MIG/SAW/SASC/ESSC

Manual /Automatic / Semi Automatic

Commonly Used Processes (Automatic)
SASC
ESSC
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SUBMERGED ARC STRIP
CLADDING (SASC)
SASC is same as SAW Process except
The Wire is replaced by Strip
SAW Wire feeding devise & Nozzle is replaced by
Strip feeding devise with guiding Shoes.
Arc is struck between strip & base metal
Arc is covered with granular Flux
Flux is fed from both sides of strip (Arc / fusion
not visible from any side)

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SUBMERGED ARC STRIP
CLADDING (SASC)
Advantages of cladding by strip over wire
- Uniform Penetration for full weld width
- Very low dilution level from base metal
- Consistent weld chemistry within the weld bead
- Flat and wide weld beads
- Less number of weld over laps
- Uniform thickness over full cladded area
- High deposition rate / High productivity
- Very low hot cracking sensitivity
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SUBMERGED ARC STRIP
CLADDING (SASC)

Flux for SASC is similar to SAW Flux
- Agglomerated
- Active / Alloyed

Prime Function of SASC Flux (Same as SAW)
- Stabilize the Arc
- Prevent the Contamination
- Even / uniform bead with out spatter
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SUBMERGED ARC STRIP
CLADDING (SASC)
Power Source
- DC Rectifiers
- Constant Voltage Characteristic
- OCV = 80 to 90V
- Current Capacity up to 1500 A - 100% duty Cycle

Strip feeding motor & feed rollers drive strip to weld pool

Strip Guiding Shoes / Nozzle
- guides the strip movement.
- Ensures even distribution of current for full width of strip
- Melts the strip uniformly for full width
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SUBMERGED ARC STRIP
CLADDING (SASC)

Strips for SASC Solid Metal / Alloy
Commonly used Austenitic SS strips :-
E309, E309L, E309Mo, E309Cb, E308, E308L,
E316, E316L, E347
Commonly used Nonferrous Alloy strips:-
Monel, Inconel, Cupronickel
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SUBMERGED ARC STRIP
CLADDING (SASC)
SASC Strip size
Width 20 to 180 mm, Thickness 0.4 / 0.5 mm
Available Standard Strip sizes
30 mm, 60 mm, 90 mm Wide 0.5 mm Thick
120 mm &150 mm 0.5 mm Are also available on request
Most Commonly used Strips
60 mm 0.5 mm & 90 mm 0.5 mm
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SUBMERGED ARC STRIP
CLADDING (SASC)
Welding Parameters
- Welding Current
- Arc Voltage
- Welding Speed
- Strip Stick Out

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SUBMERGED ARC STRIP
CLADDING (SASC)
Typical SASC Welding Parameters

Strip
Size
mm
Welding
Amp
Arc
Voltage
Speed
Welding
mm/min
Bead
Width
mm
Thickness
Per bead
mm
Deposition Rate
Kgs Per Arc Hour
30 400 22 to 24 100 to 125 32 to 36 3-5 to 4.5 7
60 750 24 to 26 100 to 125 63 to 68 3-5 to 4.5 12 -14
90 1100 26 to 28 100 to 125 94 to 98 3-5 to 4.5 17 - 20
Strips above 90 mm width are not used for SASC
Flux fed from both sides
Continuous Arcing between strip & BM
Strip cut 45 taper while staring
Stick out = 30 mm.
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SASC


+

Strip - 60 0.5
Flux
Slag
Weld
Base Metal
Hopper
Power Source
1500 Amps
Flux
+
Arc
_
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ELECTROSLAG STRIP
CLADDING
ESSC Process different from SASC

Power Source & Welding Head (Strip feeding Motor, Drive
rods, Guiding shoes, Head motion) Same as SASC

ESSC Strip Same as SAW strip (Quality marginally
different from SAW)

Quality and property of ESSC Flux totally different from
SASC.

Welding Parameters Current, Voltage, Speed - different
from SASC
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ELECTROSLAG STRIP
CLADDING
ESSC FLUX
ESSC Strip & Flux Available from
- Soudokay Belgium (Soudotape + Record )
- Sanvik - Sweden

Flux requires baking 300 to 350C for 2 to 3 Hrs.
Holding Temp Appx. 100C

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ELECTROSLAG STRIP
CLADDING
ESSC Process
Strip Electrode moves into a layer of electro conductive
molten slag
Electro conductive molten slag is formed by fusing the
electro slag flux
Very high electric current is passed through the molten
slag with very high electric resistance
Exothermic reaction when flux fuses to slag
The process generates continuous heat
Strip and base metal surface in contact with the flux, get
melted continuously
Molten strip gets deposited in molten base metal
surface
On cooling the surface gets solidified with strip metal

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ELECTROSLAG STRIP
CLADDING
Equipment & accessories same as SASC
Power Source
- DC Rectifiers
- Constant Voltage Characteristic
- OCV = 80 to 90V
- Current Capacity up to 2500 A - 100% duty Cycle
Strip feeding motor & feed rollers drive strip to weld pool
Strip Guiding Shoes / Nozzle
- guides the strip movement.
- Ensures even distribution of current for full width of strip
- Melts the strip uniformly for full width
Magnetic Steering Devise
- Generates external magnetic field/force opposite to the magnetic field of
molten weld pool
- Minimize the turbulence in weld pool
- Obtain smooth and uniform weld beads
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ELECTROSLAG STRIP
CLADDING

+

Strip - 90 0.5
Flux
Slag
Weld
Base Metal
Hopper
Power Source
2500 Amps
Flux
+
_

Magnetic steering
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ELECTROSLAG STRIP CLADDING
Base Material: SA387 Gr11 Cl2
Consumable: SS309L + SS347
Strip Size: 120 x 0.5mm
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ELECTROSLAG STRIP
CLADDING
Welding with wider strips 90, 120, 150 mm wide

Weld Pool Electro conductive With very high Current
Subjected to very high magnetic field / force
Weld metal try to flow towards centre due to magnetic force
Results in
- uneven weld bead
- Poor wetting along the toes
- Narrow weld bead
- Undercuts
- Poor slag detachability

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ELECTROSLAG STRIP
CLADDING
Magnetic Steering Devise
Generates External Magnetic Field
Equivalent and in opposite direction of
magnetic field of welding
Field generated by two solenoids placed on
both sides of stripe
Location of solenoids 15 mm away from strip
and base metal surface
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ELECTROSLAG STRIP
CLADDING
Welding with Magnetic Steering 90, 120, 150 mm wide
Magnetic Steering System (MSS) essential for strips of 90
mm and above in width
MSS desirable for 60 mm wide
MSS not required for strips below 60 mm wide
3 to 5 amps current is supplied to two solenoids / MSS
MSS generates magnetic force in opposite direction
- Results in
- Symmetric solidification line
- Smooth and uniform weld bead
- Uniform weld thickness
- Free from undercuts
- Good slag detachability

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ELECTROSLAG STRIP
CLADDING
Difference between SASC & ESSC
SASC ESSC
Flux - Agglomerated Flux Electro slag
Continuous Arc between strip & BM No Arc except in the starting
Flux fed on both side of strip Flux fed only from front side
Comparatively low Amp High Amp
Comparatively low deposition rate High deposition rate
High consumption of flux Low consumption of flux
Comparatively high penetration & dilution Low Penetration & low dilution
Minimum two layers required Single layer can also meet requirement
Arc fully covered with flux Back side fusion visible
Low hot cracking sensitivity Very low hot cracking sensitivity
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ELECTROSLAG STRIP
CLADDING
Strip Size
in mm
Welding
current
Welding
Voltage
Bead width
mm
Deposition rate
Kgs/ Arc Hr
30 550 - 650 22 - 24 32 36 10
60 1200 - 1300 23 25 63 66 22
90 1800 - 1850 24 25 93 97 33
120 2000 - 2400 24 - 25 124 - 128 42
Welding Speed = 140 to 180 mm/min
Stick out = 28 to 32 mm
No arcing except in staring
Flux is fed only in front
Strip is cut 45 taper while staring
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ELECTROSLAG STRIP CLADDING
Continuous Step Over Technique
in circumferential weld overlay
Average Deposition: 700 Kg/ Day
Base Material: SA387 Gr11 Cl2
Consumable: SS309L + SS347
Strip Size: 120 x 0.5mm
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