SOUDOKAY

STRIP CLADDING
1. INTRODUCTION

Cladding is a welding process in which a material with desired properties is

deposited on the surface of a base material. The common C/Mn or low alloyed
inexpensive base metal has mainly a load carrying function. The deposited
sophisticated material imparts surface properties such as corrosion resistance, wear
resistance, etc., to the substrate.

To the manufacturer of pressure vessels, surfacing techniques are getting more and
more important. Components reach sizes such that their fabrication calls upon the
use of clad materials.
There are different processes to obtain a clad material :
- clad plates produced by rolling which are mostly only available in standardised
dimensions and grades
- explosion clad plates
- clad plates made by welding

Among all the welding processes submerged arc and electroslag strip cladding offer
maximum deposition rate, better bead characteristics and trouble free operation
using unsophisticated welding equipment. Strip cladding is also a very flexible
process covering a very wide range of applicable materials.
The fact that in general it is used to clad finish shaped components eliminates the
eventual problems arising with cold or hot forming.

The principle of strip cladding was developed about 70 years ago (the first patent was
granted in the USA around 1920) but in Europe the process retained detailed
attention when the nuclear industry started (late 1950's).

The nuclear power industry needed a method whereby thick- wall pressure vessels
could be given a corrosion resistant inner surface.
Several modifications of submerged-arc welding with strip have been developed
mainly with a view to further increase surfacing capacity.

In the first part of this paper the SUBMERGED ARC STRIP CLADDING process will be
discussed, in the second part the ELECTROSLAG STRIP CLADDING technique will
be described. The influence of the working parameters will be given and the main
advantages and limitations will be listed.
2. THE SUBMERGED ARC STRIP CLADDING PROCESS.

2.1 Principle and main advantages

There is no essential difference between strip cladding and submerged arc

welding with wire. The conventional submerged arc equipment is also suitable
for strip cladding, basically the wire is replaced by a strip.
The welding head has to be modified so that the contact shoes and feed rollers
will take strip instead of wire.
The principle of the submerged arc strip cladding process is shown in FIG 2.
The requested energy to melt the strip and the base material is created by an
electrical arc between the welding strip and the base material under a mineral flux
protection.
The flux is added on both sides of the strip. During the process the strip and the
base metal are continuously molten under a layer of molten flux. After
solidification a shallow layer of slag covers the deposited metal.

The main advantages of the strip process over the wire processes can be
summarised as follows :

- a very uniform penetration

- low penetration level and consequently low dilution levels which enables to
reduce the number of layers to obtain the requested properties
- high and consistent quality of the deposit ; the typical solidification pattern of
the beads ensure a very homogeneous distribution of the alloying elements in
the deposited metal
- a very low hot cracking sensitivity of classic hot cracking sensitive materials
due to the absence of central solidification lines.
- very flat surface with a limited number of bead overlays
- low investment cost to switch from wire to strip
- high reproducibility
- high deposition rates
2.2. Welding equipment

2.2.1. Power sources

The power source must be of sufficient capacity to cope with high currents
(currents depending on strip size).
Considering the most widely used and standardised 60 x 0.5 mm strip, the
power source must be able to supply direct current ranging between 600 and
1000 A at 100% duty cycle.
Constant potential power sources are very well adapted they only need a
stable and independent strip feeding regulation system.
The most used power sources are CP rectifiers.

2.2.2. Welding head (motor and gear box)

Most types of wire equipment may be used for the strip cladding process.
The main factor is the ability to attach a strip nozzle.

2.2.3. Strip feeding nozzle

he strip cladding feeding nozzle plays a major role in the stripcladding
process. The nozzle guides the strip, ensures an even distribution of the
welding current over the full width of the strip and has to be able to
withstand and to dissipate the heat sufficiently to avoid overheating during
continuous operation.
TABLE 1 lists the standard Soudometal strip feed nozzles with their major
characteristics. FIGURE 3 shows the nozzle 60 DF2 (for strips up to 60 mm
wide strips).

2.4. Welding strips

The strips for submerged arc strip cladding are mostly of the solid type
having a width between 20 and 180 mm and a thickness of 0.4 or 0.5 mm.
Typical dimensions are 30, 60, 90, 120 and 150 mm, 60 mm being the most
popular one.

2.5. Main parameters - typical values

Welding current
Arc voltage
Welding speed
3. THE ELECTROSLAG STRIP CLADDING PROCESS

3.1. Principle of the process and main advantages

Electroslag strip cladding is a more recent development of the strip surfacing

technique. The principle of this process has been known for a number of years
and publications concerning its fundamentals were first published in the early
seventy's.
The principle of the Electroslag strip cladding process is shown in FIG 12 and the
bases is outlined as follows :
The basic principle is the following : A strip electrode is continuously fed into a
shallow layer of molten electroconductive slag. The heat which is needed to melt
the strip, the slag-forming flux and the surface layer of the base metal is
generated by the Joule effect as a result of the welding current flowing through
the liquid electroconductive slag. The ELECTROSLAG strip process is started in
the same way as a submerged arc cladding; the stabilisation of the process into
the electroslag mode is reached almost instantaneously.

The typical characteristics of the process are :

- the fact that the flux is fed only on the front side of the strip
- a visible weld pool at the rear side of the strip
- a radiation only in the visible and infrared spectrum, no ultraviolet radiations
because of the absence of any arc
- an additional feature (magnetic control device) is used to optimise the weld
bead profile

The main advantages of the Electroslag strip cladding process can be

summarised as follows :
- the simplicity in use is very great, in principle it needs only the same type of
equipment as the submerged arc strip cladding technique
- the electroslag technique offers much higher deposition rates compared to the
sub arc technique, at the same level of heat inputs and similar bead thickness
- the dilution with the base metal remains very low, typicaly dilution rates are
between 7 and 10 %.
- the possibility of using fewer layers to obtain the required chemical analysis
(e.g. low carbon stainless steel in a single layer).
- a very stable and regular welding process with a extremely low defects risk,
such as slag inclusions, lack of penetration,...
- a low flux consumption
3.2. Welding Equipment

3.2.1. Power sources

In view of keeping the strip feed rate and voltage variations within very
narrow limits imposed with regard to the shallow depth of the slag pool, it is
advised to use DCCP rectifiers.
Since the electroslag process requires average optimised current densities
of approx 40 A/mm2, the output of the power sources at a 100% duty cycle
has to meet high amps such as 1250 A for a 60 mm strip (typical). In
practice to obtain the required current intensity levels two power sources
can be connected in parallel. It should be checked with the manufacturer
whether given DCCP power sources can be connected in parallel without
any additional precautions.
To obtain optimum welding conditions and bead profile, it is necessary to
use a power source which will give stable voltage outputs between 21 - 27
volts.

3.2.2. Welding heads

The function of the welding head is to feed the strip at a constant speed
which is related to the welding parameters.
The strip feed rates for the electroslag process range from 1 to 2,5 m/min. In
practice no special welding heads are required to carry out electroslag strip
cladding.

3.2.3. Strip feeding nozzles

The main functions of the feeding nozzle are to guide the strip and to
maintain it in the required position during the welding operation and to
transfer the welding current from the power source to the strip by means of
appropriate contact shoes. There is no fundamental difference in design
between the sub arc and the electroslag feeding nozzle, however because of
the high current densities involved, and due to the fact the rear side of the
electroslag is subject to the heat radiation from the slag pool, their
construction is generally somewhat heavier. The electroslag nozzle is also
equipped with a water cooling possibility. FIG 13 shows the most classic
nozzle 125 ES1-300 which can be used with strip widths from 30 mm up to
120 mm width.
3.2.4. Magnetic steering device

As mentioned previously, the slag pool is electroconductive, therefore, the

slag pool is subjected to electromagnetic forces which tend to make it flow
from the sides towards the centre of the molten pool. This results in
narrower beads, more unfavorable wetting angles resulting in a more
difficult slag removal and increased risks from undercut.

To compensate this phenomenon, magnetic steering devices are used.

These magnetic field control systems works as following : an external
magnetic field generating forces of the same nature is applied but in the
opposing direction.

The external magnetic field is created by means of two solenoids,a picture

of an example of a magnetic steering device ( CED 1) with the solenoids, the
fittings to put the solenoids onto the cladding nozzle, the current cables and
the steering control box.

The location of the solenoids are very important. The tips should be placed
beside the strip electrode at a distance of approx 15 mm from the strip edge
and about 15 mm above the base material surface.

The shape of the solidification ripples should be used to control the

intensity of the magnetic field. The criterion for the correct intensity of the
magnetic fields is when the solidification lines become symmetrical. FIG 17
is an illustration of the action of the magnetic steering device on the bead
profile and on the solidification lines. In most cases the south and north
poles of the magnetic control requires different currents through each of the
solenoids.
It is obvious that the intensity on each solenoid has to be adapted to the
working conditions on a particular workpiece, taking into account any
magnetic blow effect which can not be previous calculated.
The standard magnetic steering device is capable of putting five amps on
each solenoids. For cases where the magnetic deflection from the
workpiece is intense solenoids with stronger magnetic fields have been
used (CED M 1280).
 Submerged arc strip
Electroslag strip cladding
cladding

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Comparison between
Comparaison of déposit rate SAW ESW HS SL
ESW ESW
Current ( A ) : 750 1250 1400 1250
Voltage ( V ) 26 24 24 24
Speed (cm/min ) 10 16 30 16
Dilution ( % ) 18 9 22 7

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C content (%) 0,045 0,030 0,055
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0,020
on 0.18%C Steel
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Comparison between Comparison between Solutions

Submerged arc Electroslag
SAW ESW HS SL
Two layers Two layers One layer
ESW ESW
Thickness 4.5 4.0 3.1 4.0 Product 1 0.90 0.65
(mm) (€)

Depo. Rate 14 22 27 23 Time 1 0.42 0.33

( Kg/h) ( H)

Depo. Rate 0.45 0.69 1.1 0.72 Thickness 8.0 6.2 4.0
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 24V 15 cm/min Stick-out : 30mm 1250 A 24 V Stick-out : 30mm

Bead Bead Bead Bead

thickness width Penetration Dilution thickness width Penetration Dilution
( mm) ( mm) ( mm) ( mm) Dilution
( mm ) (%) ( mm ) (%)
70 70 Bead width
0.75 15
66 0.75 15 5
Dilution Bead thickness
Penetration
5 0.50 10 4 0.50 10
Penetration
65 Bead width
0.25 5 3 65 0.25 5
4 Bead thickness
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1100 1200 1300 1400 150 200 250Ch LOUPPE
300 350 mm/min
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1250 Amp 24V 15 cm/min 1250 A 15 cm/min Stick-out : 30mm

Bead Bead Bead Bead

thickness width Penetration Dilution thickness width Penetration Dilution
( mm) ( mm) ( mm) ( mm)
( mm ) (%) ( mm ) (%)
70 70
66 0.75 15 66 0.75 15
Bead width Dilution
Dilution
5 Penetration 0.50 10 5 Penetration 0.50 10
Bead width Bead thickness
65 65
4 Bead thickness
0.25 5 4 0.25 5
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Volts
30 40 50 60 mm 24 26 28
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Variation of the chemical composition
1250 A 16 cm/min Stick-out : 30mm EST 316-1
1250 A 16 cm/min Stick-out : 30mm EST 316-1
% Cr Recycled
% Cr Val. Medi +/- 2%
Val. Medi +/- 2%

20,0
20,0
19,70
19,6 19,5 19,4 19,4
19,4 19,5
19,5 19,50
19,40

19,12
19,01 19,0
19,0 18,9
18,8
19,1 18.74

18,5
18,5
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22 24 26 28 Volts
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1250 A 16 cm/min Stick-out : 30mm EST 316-1 1250 A 16 cm/min Stick-out : 30mm EST 316-1

% Ni Val. Medi +/- 2% % Ni Recycled Val. Medi +/- 2%

13,5 13,5
13,14
13.0 13.2 13.0 12.9
13,0 12,90 13,0 13,00
12.6
12,75
12,64
12,5 12,5 12,48
12.7 12.7
12.5

22 24 Ch LOUPPE 28
26 Volts 1 2 3Ch LOUPPE 4

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1250 A 16 cm/min Stick-out : 30mm EST 316-1 1250 A 16 cm/min Stick-out : 30mm EST 316-1

Recycled
% Mo Val. Medi +/- 2% % Mo Val. Medi +/- 2%

3,0 3,0

2.63 2.63 2.60

2.60 2.60 2.61 2,66 2.60 2.61 2,67
2,61 2,62

2,5 2,57 2,5 2,57

22 24 Ch LOUPPE 28
26 Volts 1 2 3Ch LOUPPE 4

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 δ FERRITE DETERMINATION δ FERRITE DETERMINATION

The ferrite is non-uniformly distributed in a given weld

Alloy 317L C Mn Si Cr Ni Mo
Ferritscope :To a first approximation, the magnetic response of an otherwise Min value 0.027 1.25 0.44 18.6 13.0 3.7
austenitic weld metal is proportional to the quantity of ferrite present. For a industrial
cladding type 317L, an average value of 10 measurements is 8.9 FN, and the
standard deviation σ is 1.1. The Confidence interval of 95% on the average value is
VALUE 0.029 1.28 0.46 19.0 13.3 3.8
+/- 0.9 ( from 8.0FN up to 9.8 FN ) , and on the individual value is +/- 2.2 , ( from
6.7FN up to 11.1 FN ) Max value 0.031 1.31 0.48 19.4 13.5 3.9

DELONG WRC 88
Chemical composition : The amount of ferrite depend of the ferrite promoters
( such as chromium) and austenite promoters ( such as NICKEL).
Different diagrams should be used as prediction tools, the most accurate diagram is
Cr equiv. Ni equiv. Cr equiv. Ni equiv.
WRC 1992.
For standard stainless steel, the precision of the chemistry ( by spectro ), for Cr, Ni, Min value 23.0 15.6 22.3 14.6
Mo, Nb, … : is about +/- 2%, and for the other element like C, N, .. +/- 5%.
Following the AWS, variations in the results of chemical analyses encountered from VALUE 23.5 16.0 22.8 15.0
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laboratory to laboratory can have a significant effects on the calculated ferrite value, Ch LOUPPE
changing it as much as 4 to 8 FN ( SFA 5.4 A6.10.4 edition 1995) Max value 24.0 16.4 23.3 15.4
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δ FERRITE DETERMINATION DELONG

DELONG diagram
diagram

Weld déposit : 317L

Diagram Min Value Max
Delong FN 9 12 15
9 FN
Delong % 8.2 10.7 13 Ni eq.
WRC 88 6 8.6 13 16.4 15 FN
15.6

Ferritscope ( average of 10 values) Min Value Max

As welded at the surface 7.0 8 9.0
23.0 24.0
As welded at -3mm 8.0 8.9 9.8 Cr eq.

After PWHT at the surface 4.5 5.3 6.1

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After PWHT at – 3 mm 4.7 5.6 6.4
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WRC 88 diagram δ FERRITE WRC 88 diagram

Weld déposit : 347

6 FN 13 FN
Ni eq.
15.4
1
66 14
14.6

12,5
AWS : Cr , Ni : +/- 1%

11,5
14.6 Deposit : Cr eq: 19
22.3 23.3
Cr eq : max 20, min 18
Cr eq. 10,5
Deposit : Ni eq: 11,5
Weld déposit : 317L Ni eq : max 12,5, min 10,5

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22.3 18 19 20
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 Welding direction

Welding direction

Strip

Molten pool

Weld metal Ch LOUPPE Ch LOUPPE

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Setting the magnetic steering

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Setting the magnetic steering

Start with 3.5Amps at the

NORTH and 3.0 at the SOUTH
Generally, set the NORTH
magnet 0.5 to 1 Amp higher than
the SOUTH

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 Setting the magnetic steering Setting the magnetic steering

If the setting is too high, the weld

will be too wide and dip in the
If you have undercut at one middle
side, you need to increase
the current in the magnet of
this side, or decrease the If the setting is too low, the weld
current of the magnet at the will be narrower and will peak in
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other side theLOUPPE
middle
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Effect of magnetic steering Effect of magnetic steering

SOUDOTAPE 309L 60 x 0.5MM RECORD EST 122
SOUDOTAPE NiCu 7 30 x 0.5MM RECORD EST 400
1250 AMP 24 V 17CM/MIN
550 AMP 24 V 17CM/MIN

WITH OUT WITH

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S: 5A N : 5A S: 2A N : 3A
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 Adjustment of strip nozzle

Drive rolls
The spool of strip should be positioned
to feed into the nozzle without twisting
and without excessive braking on the
spool holder

Without pressure on the drive roll, the

Strip strip should run freely though the head
Put the pressure on the contact shoe,
the strip should still be able to be
pushed by hand through the nozzle
( difficult but possible )

Apply the pressure to the feed rolls up

to the strip is pushed automatically
through the contact tip, , than increase
Contact tip a little bit this pressure.
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Cable section

Strip Average Cable Bead Bead

width current section width thickn
(mm) (A) (mm²) (mm) (mm)

30 600 2x95² 32 - 37 4 - 5,2

60 1200 4x95² 63 - 68 3,5- 5,2

90 1800 5 x 95² 93 - 99 4-5

120 2400 5 x 120² 124-128

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4-5
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 Tension

Always check the tension

between the solid copper
connector and the ground

To have 24 Volt on the cladding

head, we need some time more
than 28 Volt at the power source,
( due to the section and the length
of the cables )

If we find more than 0,4V for AS or

more than 0,6V for ES between the
solid copper ground and the strip, it
is necessary to check the quality of
the connexions, the pressure on the
movable finger, the clearness of the
contacts, ( contact shoe and
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movable finger).
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Starting the weld

Cut the strip at an angle of 45° for easier starting
It is usually better to start the welding power , in view of melt a small
quantities for flux and strip before starting the travel speed.
Stopping the weld.
It is usually better to cut the travel speed, before cutting the welding power.

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 S 2°bead N
Strip S 1°bead N Welding
direction
Contact
shoe Strip

Flux only before

the strip except
when starting the
weld The surface on which you are working
Always clad in a such manner could be flat, if not, the weld will be
that the NORTH side is onto the thicker on the lower side with a steeper
SOUTH side edge which could result in a slag
entrapment when overlapping ( max
incline should be 2° )
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Strip Welding
Strip direction
Cladding 45°

Effective width
Weld
Base material Sometimes , it is necessary to produce a
cladding narrower than the strip. This
may be produced by using a strip with a
angle to reduce the effective width of the
bead
The width of the lane should The greater the angle of the strip, the
ideally have been designed narrower the bead width
to accept a single run of To maintain the same dilution and
weld with a strip at 90°. thickness of the deposit, we need to
If not, it may be necessary increased the speed ONLY.
to angle the strip as follow The new
Ch LOUPPE Chspeed
LOUPPEis be calculated as follow
. Strip width X original speed . ..
Ch LOUPPE Ch … effective width of the bead
LOUPPE

bottom dead centre

Welding direction

Rotation
STRIP
STRIP Welding direction

Vessel
Max 2°

40 – 65 mm
Always clad in a small UP HILL
position ( max 2° ) , in this case In case of cladding inside a
the weld metal flows back, and curved surface, like inside a
the base metal is exposed and shell, the strip should be in front
the penetration increase, and the of the “bottom dead centre” to
risk of lake of fusion decrease. be in small UP HILL position .
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 Starting the weld
Cut the strip at an angle of 45° for easier starting bottom dead centre
It is usually better to start the welding power , in view of melt a small Welding direction
quantities for flux and strip before starting the travel speed.
Stopping the weld. Rotation
It is usually better to cut the travel speed, before cutting the welding power. STRIP
STRIP Welding direction

Vessel
Max 2°

40 – 65 mm
Always clad in a small UP HILL
position ( max 2° ) , in this case In case of cladding inside a
the weld metal flows back, and curved surface, like inside a
the base metal is exposed and shell, the strip should be in front
the penetration increase, and the of the “bottom dead centre” to
risk of lake of fusion decrease. be in small UP HILL position .
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S 2°bead N
Strip S 1°bead N Welding
direction
Contact
shoe Strip

Flux only before

the strip except
when starting the
weld The surface on which you are working
Always clad in a such manner could be flat, if not, the weld will be
that the NORTH side is onto the thicker on the lower side with a steeper
SOUTH side edge which could result in a slag
entrapment when overlapping ( max
incline should be 2° )
Ch LOUPPE Ch LOUPPE

Ch LOUPPE Ch LOUPPE

Strip Welding
Strip direction
Cladding 45°

Effective width
Weld
Base material Sometimes , it is necessary to produce a
cladding narrower than the strip. This
may be produced by using a strip with a
angle to reduce the effective width of the
bead
The width of the lane should The greater the angle of the strip, the
ideally have been designed narrower the bead width
to accept a single run of To maintain the same dilution and
weld with a strip at 90°. thickness of the deposit, we need to
If not, it may be necessary increased the speed ONLY.
to angle the strip as follow The new
Ch LOUPPE Chspeed
LOUPPEis be calculated as follow
. Strip width X original speed . ..
Ch LOUPPE Ch … effective width of the bead
LOUPPE

1
 Soudotape NiCrMo 22
Record EST 201 C

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Mercantile
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Soudotape 625
Record
EST 201

Whitely
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Read Ltd
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CSI
SOUDOTAPE 420 Record EST 420

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2
 Gas tube plate
surfaced with
Valves
ESW using
cladded with
Soudotape Soudotape 625
625 (30*0.5) and Record
and Record EST 201
EST 236 cooler
(ESW) and
Record NFT
201 (SAW)

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Offshore
ESW dia
800mm- separator vessel
wallthickn (dia 2.5m) using
40mm , length Soudotape
4m) NiCu7
Using (60*05)and
Soudotape Record EST
24.12LNb with
Record EST 400.
136
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Tube for
process furnace Vessel
(dia 2.6m, bottom
lenght 4.5m, overlayed
wall thickn with the
40mm – ESW
Cladded with process
Soudotape using
NiCrMo 7 Soudotape
(60*0.5) and 21.13.3L
Record EST
(60*0.5)
201C (alloy C4)
and Record
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EST 122.

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 ESW surfacing
of chemical
vessel with Electroslag strip
316L using cladding with
Soudotape 625
Soudotape
(30*0.5) and
316L and
Record EST 236
Record EST (pipe dia approx
316-1 45 cm)

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ESW Conical
surfacing of carbon
chemical crusher
vessel with overlaye
316L using d with
Soudotape
316L and
Soudotap
Record e 625
EST 316-1 and
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Record
NFT 201
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Paper industry Reconstitution of Cu Ni 90/10 cladding

roll surfaced One layer
Chemistry of the cladding deposit : Cu : 80 % Ni : 18 % Fe : 2%
with ESW
using
2mm

Soudotape 430
(60*0.5) and
10mm

Record EST
452 (3 layers -
surface
hardness
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370HB
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