THE NEW DIMENSION IN STRIP CLADDING www.lincolnelectric.eu THE NEW DIMENSION IN STRIP CLADDI

THE COMPLETE SOLUTION FROM A SINGLE SOURCE THE NEW DIMENSION IN STRIP CLADDING

70% Time and 40% Cost Saving − Always Single Layer Solution − High Speed Cladding Process Homogeneous and Cleaner Chemistry − <5% Fe in Ni-625 − Improved Quality Full Process Control − tate-of-the-Art Digital Hybrid 3D Z5 Controller S − eal Time Data Logging and Traceability R First Proven Single Layer High Speed Solution with Neutral Flux − <5% Fe in Ni-625 − equired Undiluted AWS Chemistry for Stainless Steel R Reduction in Working Capital − ingle Stainless Steel Strip for All Austenitic SS Grades S − aster Delivery of MCW and Full Control of Delivery Time F Instant Technica

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SPECIAL ALLOYS~ STRIP CLADDING PROCESSES SUBMERGED ARC STRIP CLADDING ELECTRO SLAG STRIP CLADDING TOTAL SOLUTION FOR STRIP CLADDING UHRHAN-SCHWILL SCHWEISSTECHNIK ABOUT LINCOLN ELECTRIC

STRIP CLADDING PROCESSES INTRODUCTION Cladding is a fundamental process in the Fabrication industry and is applied across the whole spectrum of applications – from the nuclear, oil and gas industries to petrochemicals and steelmaking. Cladding is required on the process side of high pressure Critical Process Plant Equipment (CPE) to provide corrosion resistance against highly severe corrosive service fluid or to increase wear resistance of a component being subjected to heavy wear and tear applications e.g. continuous casting rollers in Steel mills. While CMn substrates, low alloy steels and...

LADDING PROCESSES There are two conventional strip cladding processes – Submerged Arc and Electro Slag. SUBMERGED ARC STRIP CLADDING Submerged • Utilises an arc that runs back and forth at high speed along the strip. Arc Strip Cladding (SASC) • The arc causes more penetration into the base material, resulting in dilution levels of ~20%. • Deposition rate: 12-14 kg/h for 60x0.5mm strip. • Current range restricted to limit dilution. Fixed contact shoe Liquid slag Flux hopper: 2 Weld metal Flux height Penetration /dilution WELDING DIRECTION

Submerged Arc Strip Cladding (SASC) Fixed contact shoe Liquid slag Flux hopper: 2 Weld metal Slag Penetration /dilution Flux height ELECTRO SLAG STRIP CLADDING WELDING DIRECTION • Arc-Less process – uses conductive flux and works on Joule’s resistance heating principle. • The strip current passes through the molten slag. The resulting resistance heating effect melts the strip and deposits the molten weld pool onto the base material. Electro Slag Strip Cladding (ESSC) • Low dilution level (9 - 12%). Process has significant advantages over SAW. Fixed contact shoe Movable finger Liquid slag open...

WELDING DIRECTION Electro Slag Strip Cladding (ESSC) Fixed contact shoe Movable finger Liquid slag open pool Weld metal Stick-out: stronger influence Slag thinner THE NEW DIMENSION IN STRIP CLADDING Flux height AG STRIP CLADDING Penetration /dilution much lower vs SAW WELDING DIRECTION tent Pen ding • New variant of ESW process State-of-the-art technique – first introduced by Lincoln Electric • • Hot metal cored wires added to the molten pool as 3 constituent • Consistently achieves <5% Fe in single layer for Ni-625 alloys Hybrid Electro Slag Cladding (HEC)* • Always in single layer coupled with...

COMPARISON BETWEEN SUBMERGED ARC, ELECTRO SLAG – CONVENTIONAL AND H-ESC* Submerged Arc Strip Cladding (SASC) Submerged Arc Strip Cladding (SASC) Minimum number of layers in Deposition Ni-625 Flux type rate (kg/h) to achieve for high speed 60x0.5 mm Welding speed <5% Fe cladding strip (cm/min) chemistry in single layer Electro Slag Strip Cladding (ESSC) Submerged Arc Strip Cladding (SASC) Normal speed: 15-18 High speed: 24-35 Strip Strip + + Metal Cored Wire Metal Cored Wire ++ ESW Flux ESW Flux Neutral Neutral Electro Slag Strip Cladding (ESSC) Hybrid Electro Slag Cladding (HEC)* Hybrid Electro...

HYBRID TECHNIQUE* MAIN BENEFITS ADDITIONAL BENEFITS Less dilution: always achieves cleaner chemistry in a single layer Ni-625: <5% Fe Stainless steel and other Ni alloys: required AWS undiluted chemistry High Speed Single Layer Solution – eliminates one full layer Less welding time: faster completion Savings in labor costs: more competitive S avings in NDE costs and time by eliminating one additional layer Highest Deposition Rate (1.3-1.5 x) Higher stick-out Higher current Additional deposition from hot MCW Single Flux Solution Neutral flux 3D CladFlux E200: single flux for all Ni alloys 3D CladFlux...

COST BENEFIT ANALYSIS - Ni-625 [TYPICAL] INLET SEPARATOR Electro Slag High Speed (HS) • The new Hybrid Solution saves an enormous amount of time • Releasing valuable workshop hours for fabricating more equipment within the same period • Hybrid is the only existing single layer solution that guarantees Fe <5% in Ni-625 alloy • Additional saving in time and cost due to elimination of NDE • Eliminates use of alloyed flux • The savings from one project will cover the costs of the investment 12 THE NEW DIMENSION IN STRIP CLADDING www.lincolnelectric.eu

TOTAL SOLUTION FOR STRIP CLADDING The most important key to the success of Strip cladding process is to have the right combination of: Welding Consumables i.e. Strip, Flux and Wire (where applicable) Cladding Head Magnetic Steering Devices Welding Power Sources and Strip Feeding Device Hot Wire Feeding Mechanism Automatic Welding Control System If even one of these key elements is absent, the process is likely to fail in achieving its desired output. Lincoln Electric is the world leader, as it has top quality solutions and the desired expertise in all the above fields. WELDING CONSUMABLES TOTAL...