Strip Cladding

Lewis Ashby
7th December 2016

voestalpine Bhler Welding

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www.voestalpine.com/welding

We are part of voestalpine AG

Tool steel & leading Turnouts, rails,
position for high-speed processed wire,
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forged parts welding consumables

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Welding: 545 Mio EUR | 2,397 Employees

Steel Division Metal Forming Division

Premium steel High-quality metal
strip, electrical processing solutions,
steel strip, heavy precision steel strip &
plate, cast products special components

11,2 Billion EUR | 47,418 Employees

voestalpine Bhler Welding

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More than 145 years of know-how
mergers & acquisitions
of best-in-class welding companies:
Thyssen, Bhler, UTP, Avesta Welding,
Soudokay, Fontargen, Fileur, Maruti

in the steel
a voestalpine
industry
company
since 1870
since 2007

in the welding
consumables business
since 1926

voestalpine Bhler Welding

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Production sites in Europe

Malm | Sweden
Hamm | Germany 1,200 tons annual capacity
55,000 tons annual capacity Filler metals and fluxes for
Stick electrodes, solid wire, flux brazing and soldering

Eisenberg | Germany Bad Krozingen | Germany

400 tons annual capacity 3,000 tons annual capacity

Filler metals and fluxes for Stick electrodes, Thermal

brazing and soldering spraying powders

Kapfenberg | Austria
27,000 tons annual capacity
Flux cored wire, stick electrodes,
Seneffe | Belgium solid wire
7,500 tons annual capacity
Hardfacing flux cored wire for Cittadella | Italy
maintenance & repair, Welding fluxes 6,000 tons annual capacity
for maintenance & repair, Strips for
strip cladding process Seamless flux cored wire

voestalpine Bhler Welding

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 voestalpine Bohler Welding UK Ltd
Oldbury Nr Birmingham

Sales Customer Service Technical Support Product Distribution

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3 Business Units - 3 Brands

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Comprehensive portfolio
Products Alloys / Grades
Covered electrodes Unalloyed and low
alloyed
Solid wires/TIG rods
Aluminium
Flux cored wires
Nickel-based alloys
Sub arc wire and flux
Special alloys
Strips for strip cladding (nickel, copper, cobalt)
Solders, pastes, fluxes Stainless steel
Post-weld cleaning High strength
chemicals and pickling High / low temperature
pastes Corrosion resistant
Thermal spraying Heat resistant
powders

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Certificates

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 ASME NCA 3800

voestalpine Bhler Welding

9 | | Corporate Presentation

Why cladding?

One single material cannot comply with all

the requirements
Solution : combining two materials
Strip cladding
Frame : un or medium alloyed construction
steel to support the main mechanical loads
Electroslag
of the vessel (base metal)
Side subjected to wear : alloyed or medium
Cladding
alloyed cladding with anti-wear properties

Corrosion
High temperatures
Metal to metal
Compression loads
voestalpine Bhler Welding Abrasion Base metal
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Methods of protecting a vessel inside structure from
corrosion
1. High alloyed steel inner sleeves

CRA Sleeve

Vessel shell

US Patent
voestalpine Bhler Welding
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Methods of protecting a vessel inside structure from corrosion

2. Roll-bonded clad plates

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Methods of protecting a vessel inside structure from corrosion

3. Explosive bonded cladding Vd=2-3.5 km/s

Vc=0.2-0.5 km/s

Some Explosives used for Detonation Laminar transition

bonded cladding velocity
(km/s) Vd 1.8km/s
Vd = 1.8 km/s Vd = 2.1 km/s

RDX (Cyclotrimethylene trinitramine C3H6N6O6) 8.750

PETN (Pentaerythritol tetranitrate C5H8N4O12) 8.400

Wavy transition
TNT (Trinitrotoluene C7H5N3O6) 6.900
Vd = 2.5 km/s Vd = 2.8 km/s
Tetryl (Trinitrophenylmethylinitramine C3H6N6O6) 7.570
Vd=explosive detonation velocity
Lead azide (Pb(N3)N2) 4.630

Amonium nitrate (NH4NO2) 5.270 Turbulent transition

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Methods of protecting a vessel inside structure from corrosion

3. Explosive bonded cladding

Open air explosion cladding:

Lower costs,
Entrapped
Intermetallic oxides Lower bonding quality

Hammer bend tests Explosion cladding under vacuum:

Highest costs
Vacuum EXW Open air EXW Zones of potential risk of crack formation depending of
oxides and/or intermetallics entrapments in wave crests Best bonding quality

Cladding Clad material

Fine grain region EXW Superduplex
20-30 microns
Amorphous structure 0.02-0.5 microns Heat exchanger
voestalpine Bhler Welding High dislocation density 20-30 microns
14Base
| metal | Base metal
Onzawa explosion bonded model.

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Methods of protecting a vessel inside structure from corrosion
3. Strip cladding
Derived from common SAW
Wire : solid or cored

Heat source :
Agglomerated Flux
Subarc = Electric arc

Electroslag = Slag ohmic

resistance

Electrical Power
Source
Base metal

voestalpine Bhler Welding

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Submerged Arc Strip Cladding (SASC)

Driving rolls Strip

Travel direction
Contact shoes Flux hopper 2
Flux hopper 1

Liquefied slag layer

Agglomerated flux Solidified slag layer

Clad metal
Base metal

Electrical arc heating the weld pool

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Electroslag Strip Cladding (ESSC)

Contact shoes
Strip Driving rolls
Single flux hopper
Travel direction

Liquefied electroconductive slag layer

Solidified slag layer
Agglomerated flux
Clad metal
Base metal
Weld pool heated by RxI2
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ESSC Process explained

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Cladding Nozzles

voestalpine Bhler Welding

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Magnetic Steering

voestalpine Bhler Welding

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Comments on Heat Input

Amperage x Voltage x 60
Processes using wires* or SMAW* HI =
Expressed in Joules/cm
Travel speed (cm/min)

Amperage x Voltage x 60
Processes using strips HI =
Expressed in Joules/cm2 Travel speed (cm/min) x strip width (cm)

Welding process I (Amps) U (volts) speed HI (J/cm)

SMAW (1) 100 24 20 7200
SAW (2) 650 32 55 11345
SAW strip (3) 750 26 12 16250
ESW strip (3) 1250 24 22 13636
(1) Stick electrode 3,25 mm diameter, bead width = +/- 10 mm
(2) Submerged arc welding wire, bead width = +/- 20 mm
voestalpine Bhler Welding
(3)
* : 60
21 | mm
only strip
valid width;| bead
for stringer width = +/-63mm
weld beads

Characteristics of strip cladding

: Very uniform penetration

Low dilution levels

High deposition rates

Homogeneous weld metal

Low crack sensitivity

Very flat surface

High reproducibility

Low flux consumption

Highly flexible cladding process

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 Very uniform penetration

Low dilution levels

High deposition rates Single layer cladding with wire

stringer beads
Homogeneous weld metal
Multiple layers cladding with wire
Cladding
Low with Wire
crack sensitivity stringer beads

Very flat surface Multiple layers cladding with wire

weaved beads
High reproducibility
Single layer cladding with strip
Low flux consumption
Cladding with stringer beads
Highly Multiple layers cladding with strip
Stripflexible cladding process
stringer beads
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Very uniform penetration

Low dilution levels

High deposition rates Typical values: A

Homogeneous weld metal SASC: 18%
Low crack sensitivity
ESSC: 10% B
B
Very flat surface Dilution
A B
High reproducibility
Base metal 0.20 wt% C, Dilution level : 10 %
Low flux consumption
Strip 0.015 wt% C
Highly flexible cladding process
C in 1st layer = 0.20 x 10% + 0.015 x 90% = 0.034 wt%
voestalpine Bhler Welding
24 | | C en 2nd layer = 0.034 x 10% + 0.015 x 90% = 0.017
wt%

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 Very uniform penetration

Low dilution levels

Subarc SC deposition rate spectrum High deposition rates

kg/h
SMAW Homogeneous weld metal
SAW with 1 single wire
SAW with 2 wires
Low crack sensitivity
FCAW
PLASMA SPRAYING
PLASMA MIG Very flat surface
GMAW
SASC with 60mm strip
SASC with 90mm strip High reproducibility
SASC 120mm strip
ESSC with 60mm strip
ESSC with 90mm strip
Low flux consumption
ESSC with 120mm strip
Highly flexible cladding process
Electroslag SC deposition rate spectrum

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Very uniform penetration

Low dilution levels 625 GMAW

wire overlay
High deposition rates
cladding

Homogeneous weld metal

Low crack sensitivity

Evolution of the content in alloying elements for
a single layer 625 cladding made with Electroslag SC
Very flat surface
Percentagein alloying

120
Nb Cr Fe
100 Mo Ni Si
1st layer
elements

80 Mn

High reproducibility
Single layer 625 strip cladding
60
Base weld metal
40
20

Low flux consumption 0 metal

-100

100

150

200

250

300

350

400

450
0

50
-50

Distance from the fusion line [m]

Highly flexible cladding process
C-steel base metal

voestalpine Bhler Welding Fusion line

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Very uniform penetration

Low dilution levels

High deposition rates CaO + MgO

+ CaF
Raw 2 + Kwith
materials 2 O +Basic
Na 2Obehaviour
+ 1 FeO + MnO
M CaO M MgO M CaF M K O M Na O 2 M FeO M MnO
I B (%mol.) = 2 2 2

TiO 2 Al2O3
Homogeneous weld metal RawSiO 2 + 1 with
materials + behaviour
Acid
M SiO 2 M TiO M Al O
2 2 2 3

Low crack sensitivity

Very flat surface The higher the basicity index, the better the
metallurgical cleaning efficiency of the weld pool
Typical SC Flux basicity indexes
High reproducibility

Low flux consumption

Subarc : I = 0.92.2
B

Highly flexible cladding process

Electroslag : IB = 4
Vertical molten metal solidification pattern

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Very uniform penetration

Low dilution levels

High deposition rates

Homogeneous weld metal

Low crack sensitivity

Very flat surface

High reproducibility
Heavy influence on

Low flux consumption post weld machining costs

Highly flexible cladding process

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 Very uniform penetration
Low dilution levels
High deposition rates
Homogeneous weld metal
Low crack sensitivity
Very flat surface
High reproducibility
Typical values observed in cladding applications:
Low flux consumption
Highly flexible cladding process
voestalpine Bhler Welding
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Very uniform penetration
Low dilution levels
High deposition rates
Homogeneous weld metal
Low crack sensitivity
Very flat surface
High reproducibility
Low flux consumption
Most flexible cladding process
voestalpine Bhler Welding
30 | | flux
ESSC Relative
Nominal
Absolute
variation variation
Voltage 24V +/- 0.5V +/- 2%
Amperage 1250A +/- 50A +/- 4%
SAW wire: 0.8-1 kg melted flux /kg melted wire
SASC strip: 0.8 kg melted flux /kg melted strip
ESSC strip: 0.5- 0.75 kg melted flux /kg melted strip
Immediately applicable
on vessels during manufacturing
operations even on complex
and narrow areas & shapes
Allows to restore an existing
cladding on bonded clad
plates after forming &
joint welding
Virtually no limit of accessible 0.5Mo, 1,25Cr-0.5Mo, 2.25Cr-1Mo,410,
chemical compositions in stainless
308L,309L,316L,347,22 9 3L, 25 8 4 L
Steels, Ni-bases, Cu-bases
Co-bases thanks to judicious Alloy 625, Alloy 825, Monel 400.
choices in strip & flux combinations
& composition adjustments by the
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Main paramtres & essential diffrences
60 x 0,5mm strip
SASC ESSC
4.5mm thick of dep. met.

Electrical arc Yes No

Source of heat Electrical arc Joule-effect in molten slag

Current 750 A 1250 A

Typical welding Voltage 28 V 24 V

parameters

Travel speed 12 cm/min 18 cm/min

Current density in strip 25 A/mm 42 A/mm

Dilution 18 % 10 %

Deposition rate Bhler Welding

voestalpine 14 kg/h, 0.4 m2/h 23 kg/h, 0.6 m2/h
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Magnetic control No Yes

Standard SA strip cladding solutions for 347

Using standard stainless steel strips at conventional travel speeds

Composition
Two layers : alloy 347 mm FN
C Mn Si Cr Ni Nb
Soudotape 309 L
1st L 0.045 0.9 0.8 18.2 9.7 - 3.3 2 2
Record INT 109
Soudotape 347 layers
2nd L 0.035 0.8 0.9 19.3 10.0 0.4 3.1 6
Record INT 109

60 mm strip: 750 A - 28 V - 14 cm/min [ 5.9 inch/min] - 14.4 kg/h [ 31.7 lbs/h] - 0.58m2/h [ 898 inch2/h]

RECORD INT 109 : Neutral flux

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Standard ES strip cladding solutions for 347

Using standard stainless steel strips at conventional travel speeds

Two layer alloy 347 Composition

mm FN
C Mn Si Cr Ni Nb
Soudotape 309 L
1st l 0.03 1.26 0.42 19.3 10.2 - 5 2 2
Record EST 122
Soudotape 347 layers
2nd l 0.02 1.33 0.41 19.1 10.2 0.37 5 6
Record EST 122
Soudotape 347 1 single
1st l 0.03 1.3 0.58 19.0 10.4 0.35 4 5
Record EST 347-1
60 mm strip: 1250 A - 24 V - 16 to 18cm/min [7.1 inch/min] - 24 kg/h [ 52.8 lbs/h] - 0.75m2/h [ 1160 inch2/h]
layer

RECORD EST 122 : Neutral flux

RECORD EST 347-1 : Cr,Ni,Nb compensated flux

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Standard ES strip cladding solutions for 347

Using over alloyed stainless steel strips at conventional or high travel speeds

Composition
Single layer alloy 347 mm FN
C Mn Si Cr Ni Nb
Soudotape 21 11 LNb
1st L 0.030 1.4 0.4 19.0 10.1 0.4 4.8 7
Record EST 122 (1)
Soudotape 24 12 LNb
Single
1st L 0.045 1.4 0.4 19.3 10.5 0.5 3.1 6
Record EST 136 (2) Layer
Soudotape 21 11 LNb
1st L 0.039 1.2 0.4 18.3 9.3 0.5 2.8 5
Record EST 347-1 HS (3)
60 mm strip: (1) : 1250 A - 24 V - 16 cm/min [6.3 inch/min] - 24.0 kg/h [ 52.8 lbs / h] - 0.62 m2 /h [ 967 inch2/h]
(2) : 1450 A - 24V - 35 cm/min [13.8 inch/min] - 27.8 kg/h [ 61.3 lbs / h] - 1.12 m2 /h [ 1737 inch2/h]
(3) : 1650 A - 24V - 35 cm/min [13.8 inch/min] - 31.6 kg/h [ 69.7 lbs / h] - 1.41 m2 /h [ 2188 inch2/h]

RECORD EST 122 & 136 : Neutral fluxes

RECORD EST 347-1 HS : Cr,Ni,Nb compensated flux
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Developed ES fluxes for single layer cladding at conventional* travel speeds
* : 15 -18 cm/min
Alloy Grades Layers Welding Strip Single layer flux

AISI 308L 1 Soudotape 308L RECORD EST 308-1

AISI 309L 1 Soudotape 309L RECORD EST 309-1

AISI 316L 1 Soudotape 316L RECORD EST 316-1

AISI 317L 1 Soudotape 21.13.3L RECORD EST 317-1

AISI 347 1 Soudotape 347 RECORD EST 347-1

AISI 385 1 Soudotape 20.25.5LCu RECORD EST 385-1

Ni-alloy 625 1 Soudotape 625 RECORD EST 625-1

Ni-alloy 825 1 Soudotape 825 RECORD EST 138

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Duplex 2209 / 1.4462 1 Soudotape 22.6.3L RECORD EST 4462-1

Developed ES combinations for single and multilayers high* speed cladding

* : 35 cm/min
Alloy Grades Layers Welding Strip High speed flux

AISI 308L 2 Soudotape 309L/308L RECORD EST 136

AISI 316L 2 Soudotape 309L/316L RECORD EST 136

AISI 316L 1 Soudotape 21.13.3L RECORD EST 316-1HS

AISI 317L 2 Soudotape 21.13.3L RECORD EST 136 Mo

AISI 347 1 Soudotape 24 12 LNb RECORD EST 136

AISI 347 1 Soudotape 347 RECORD EST 347-1HS

Ni-alloy 600 2 Soudotape NiCr3 RECORD EST 236

voestalpine Bhler Welding
36 | 625
Ni-alloy | 2 Soudotape 625 RECORD EST 236

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Comparison between flux technologies
* : Based on a 2 layer deposit

Comparison by process :
Based on 60x0,5mm strip SAW ESW ESW HS ESW SL

Voltage (Volts) 28 24 24 24

Current (Amps) 750 1250 1450 1250

Speed (cm/min) 10-12 16 35 18

Thickness/layer (mm) 4,5 5.0 3,0 4,5

Deposition rate (kg/h) 14 22 27 23

Covering rate (m/h) 0,45 0,69 1,1 0,7

Min. required number of layers 2 1-2 1-2 1

Need of magnetic steering No Yes Yes Yes

C % in 1st layer on
mild steel metal 0,045 0,030 0,055 0,020

voestalpine
Consumables Bhler
costs Welding 100% 80% 85% 65%
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Working time 100%* 66%* 42%* 33%

Single layer strip cladding of 316L at high speed

Flux : RECORD EST 316-1 HS (6717)
Strip : SOUDOTAPE 21.13.3L (95937, EF2065, 60x0,5 mm)
Base metal : ST 52 (thickness : 30 mm)

Welding position: 1G/PA Flat STRIP WELD AWS A5.4:

% ANALYSIS OVERLAY E316L
Polarity: DC (+)
C 0.011 0,034 0,04
Welding current: 1700 A Mn 1.63 1,16 0,5-2,5

Si 0.23 0,30 1,00

Arc voltage: 24 V
S 0.001 0,005 0,03
Travel speed: 30 cm/min P 0.019 0,017 0,04

Preheat/ interpass temperature: none / Max. 150 C Cr 20.25 19,4 17,0-20,0

Ni 14.3 13,2 11,0-14,0

Stick out: 40 mm
Mo 2.9 2,96 2,0-3,0
Number of layers: 1 Cu 0.04 0,03 0,75

Number of runs: 2 FN - 8,7 -

Bead overthickness
voestalpine Bhler Welding 5 mm
Bead| width | 65 mm

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voestalpine Bhler Welding
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voestalpine Bhler Welding
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voestalpine Bhler Welding
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 voestalpine Bhler Welding
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Thanks for your kind attention

Please visit our website using the below links to download our Nuclear Industry Brochures.
http://www.voestalpine.com/welding/content/download/3459/57404/file/Welding+Solution
s+for+the+Nuclear+Industry+%28EN%29.pdf

http://www.voestalpine.com/welding/content/download/3460/57407/file/Filler+Metals+for+the+Nucl
ear+Industry+%28EN%29.pdf

ANY QUESTIONS ?

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