Lincoln Electric : Cladding

Applications
 SAW (SA) Strip Cladding Electro slag (ESW) Strip
Cladding

Lincoln Strip Cladding head can perform both SAW/ESW
strip cladding

With ESW process we can achieve Limited dilution into the base
material, typically 10% (compared with 20% SAW for 60x0.5mm strip).
Leading to the ability to deposit single layer full chemistry with over
alloyed strip.

Electro slag refining occurs when the molten metal passes through the
slag bath, resulting in cleaner weld metal with lower Oxygen levels.

In ESW process, Higher current levels can be used giving deposition

rates of 22-25kg/hr for 60mm wide strip. (SAW 10-12kg/hr) Utilising high
speed fluxes, dilution levels can be reduced and the area coverage (m2/hr)
can be increased
Lincoln Electric Strip cladding consumables:
from Metrode – A Lincoln Electric Company from UK
 ES200. Typical strip/weld deposit analysis, wt%
Strip/Flux Layer C Mn Si Cr Ni Mo Nb N Cu Fe FN/

EQ316L OA Strip 0.014 1.66 0.18 20.56 13.31 2.85 0.01 0.04 0.12 bal

EQ316L OA first layer 0.020 1.49 0.30 19.40 12.85 2.72 0.01 0.04 0.01 bal 8

EQ347 OA Strip 0.011 2.00 0.29 21.39 11.30 0.13 0.63 0.03 0.31 bal

EQ347 OA, first layer 0.028 1.52 0.43 19.54 10.40 0.12 0.46 0.04 0.27 bal 7

EQ308L Strip 0.015 1.76 0.32 20.10 10.35 0.07 0.05 0.03 0.05 bal

EQ308L second layer 0.016 1.47 0.47 19.32 9.95 0.07 <0.01 0.03 0.05 bal 8

EQ347 Strip 0.023 1.85 0.20 20.01 10.81 0.05 0.53 0.02 0.05 bal

EQ347 second layer 0.021 1.51 0.38 19.38 10.47 0.05 0.42 0.02 0.04 bal 7

EQ309L Strip 0.015 1.48 0.38 23.66 13.27 0.08 0.013 0.05 0.04 bal

EQ347 Strip 0.023 1.85 0.20 20.01 10.81 0.05 0.53 0.02 0.05 bal

EQ309L/EQ347 first 0.027 1.29 0.53 21.08 12.06 0.08 0.009 0.03 0.04 bal 7
layer EQ309L

EQ309L/EQ347 second 0.018 1.45 0.42 19.90 10.78 0.05 0.36 0.03 0.04 bal 7
layer EQ347

EQ62-50 Strip 0.006 0.042 0.045 21.80 bal 8.89 3.26 - 0.09 0.48 -

EQ62-50 second layer 0.006 0.06 0.35 21.10 bal 8.78 3.08 - 0.09 2.07

EQ82-50 Type 0.007 0.76 0.34 22.37 39.01 3.00 - 1.72 31.30 -

EQ82-50 (type) third 0.012 0.65 0.77 22.45 39.05 2.64 - - 1.68 32.15
layer
 ES400. Typical strip/weld deposit analysis, wt%

Strip/Flux Layer C Mn Si Cr Ni Mo Nb N Cu Fe FN/

EQ347 Strip 0.023 1.85 0.20 20.01 10.81 0.05 0.53 0.02 0.05 bal

EQ347/ES400 third layer 0.017 1.43 0.32 19.75 10.57 0.05 0.41 0.03 0.06 bal 8

EQ308L Strip 0.015 1.76 0.32 20.10 10.35 0.07 0.05 0.03 0.05 bal

EQ308L/ES400 Three 0.015 1.44 0.45 19.58 10.32 0.07 0.09 0.03 0.09 bal 8

EQ62.50 Strip 0.006 0.042 0.045 21.80 bal 8.89 3.26 - 0.09 0.48 -

EQ62.50/ES400 third 0.006 0.07 0.29 21.15 bal 8.83 3.21 - 0.08 1.22 -
layer

EQ82.50 Type 0.007 0.76 0.34 22.37 39.01 3.00 - 1.72 31.30 -

EQ82.50 (type)/ES400 0.010 0.97 0.74 22.44 39.12 2.64 - - 1.69 32.27 -
third layer
Dilution
The level of dilution is dependent on the amount of penetration into the base material and is
process related. Typical levels are as follows:

SMAW: 25-30%
SAW Wire: 25-35%
SAW Strip: 18-25%
ESW Strip: 8-12%

Overlapping with the adjacent bead will reduce the apparent dilution and steady state conditions
are achieved after the third run.

A Overlay

B Base material penetration

Dilution % = B___
A+B
Where A= the area above the plate and B= the area penetrated in the plate thickness

Individual element can be calculated as follows knowing the dilution level (or estimation of)

Ec = (Bc x D%)+[(Sc + Av)x(1-D%)]

100 100
Ec Element concentration in cladding
Bc Element concentration in base material
D% Dilution %
Sc Element concentration in strip
Av Alloying vector
Flux/Strip C Mn Si Cr Ni Mo Nb
ES200/EQ308L 0 -0.34 +0.14 -0.48 0 0 -
ES200/EQ347 0 -0.38 +0.19 -0.34 0 0 -0.1
ES400/EQ308L 0 -0.32 +0.13 -0.52 0 0 -
ES400/EQ347 0 -0.42 +0.12 -0.26 0 0 -0.1
ES200/EQ62-50 0 0 +0.23 -0.69 0 0 -0.2
ES400/EQ62-50 0 0 +0.25 -0.65 0 0 0
 Penetration Deposition Rate
0.8 16
0.7 14
Penetration, mm

0.6 12
0.5 10

kg/hr
0.4 8
0.3 6
0.2 4
0.1 2
0 0
200 300 400 500 600 700 800 200 300 400 500 600 700 800

Current, A Current, A

Dilution%
16
14
12
Dilution,%

10
8
6
4
2
0
200 300 400 500 600 700 800

Current, A
 Penetration Deposition rate
0.7 16

0.65 15
Penetration, mm

0.6 14

kg, hr
0.55 13

0.5 12

0.45 11

0.4 10
23 24 25 26 27 28 29 23 24 25 26 27 28 29

Voltage Voltage

Dilution
16
14
12
Dilution, %

10
8
6
4
2
0
23 24 25 26 27 28 29

Voltage
 Penetration Dilution
0.8
19
0.7
17
Penetration, mm

0.6
15

Dilution, %
0.5
0.4 13
0.3 11
0.2 9
0.1 7
0 5
130 150 170 190 210 230 130 150 170 190 210 230
Travel Speed mm/min Travel Speed mm/min
 25
1
0.9
20

Deposition rate,kg/hr
0.8
Penetration, mm

0.7
15
0.6
0.5 Steel
Steel
10
0.4 308L
308L
0.3 625
625 5
0.2
0.1
0
0
0.2 0.3 0.4 0.5 0.6 0.7 0.8
0.2 0.3 0.4 0.5 0.6 0.7 0.8
Strip Thickness, mm
Strip Thickness, mm

20
18
16
14
Dilution, %

12
10 Steel
8
308L
6
625
4
2
0
0.2 0.3 0.4 0.5 0.6 0.7 0.8

Strip Thickness, mm
 Penetration Deposition Rate
0.7 25
0.6

Deposition Rate, kg/hr

20
Penetration, mm

0.5
0.4 15

0.3 10
0.2
5
0.1
0 0
0 10 20 30 40 50 60 70 0 10 20 30 40 50 60 70

Strip Width ,mm Strip Width ,mm

Dilution
15
14
13
12
Dilution, %

11
10
9
8
7
6
5
0 10 20 30 40 50 60 70

Strip Width ,mm

 Heat Input (kJ/mm2) = AxVx60
Sx1000xW

Process Strip width- Bead A V Travel kJ/mm kJ/mm2

wire ø, mm Width, speed
mm mm/min

SAW Wire 4.0 20 550 32 457 2.3 0.12

SAW Strip 60x0.5 65 750 26 140 8.35 0.13

ESW Strip 60x0.5 70 1250 25 180 10.41 0.15

Strip width Minimum Vessel ID minimum cladding, Vessel OD minimum cladding,
mm base material mm mm
thickness,
mm
Longitudinal Circumferential Longitudinal Circumferential
30 30 200 300 400 250
60 45 460 700 500 500
90 75 660 1070 1000 1300
120 100 960 1940 1500 2400

20

15
Dilution %

10

0
-6 -4 -2 0 2 4 6

Inclination of Parent Material, °

15°
A
Direction of
Current
Flow

Direction of
slag flow
 South
Magnet

Current

Magnetic
Motion
Field

Travel Direction
North
Magnet
 Control Cable

Parallel Electrode cable Lincoln

connection connected to strip NA5
cable Lincoln nozzle Digital
DC 1000 controller
Slave power NA5 S wire
source feeder
Strip reel
drum
Lincoln
DC 1000
Master Power
Source Flux hopper

Earth Cable
connected to
work
 Strip
cladding
Head for
10mm
to
30mm
strips
 Strip
cladding
Head for
30mm
to
60mm
strips
 Strip
cladding
Head for
60mm
to
120mm
strips

The required current rating for different strips

 for 30 X 0.5mm strip – 750A, 25V

 for 60 X 0.5mm strip – 1150-1250A, 25V
 for 90 X 0.5mm strip – 1750A, 25V
 for 120 X 0.5mm strip – 2250A, 25V

The minimum strip width available in the market is 15mm.

Instead of going for 15mm or 10mm strip, we can use the twin wire system
with ESW process to achieve the required results.

When you use 60mm strip, the minimum required current is 1250 amps, so
you can go for 2 sets of DC1000amps machine connected in parallel to achieve
the required current. And with the same parallel connected power sources you
can use maximum of 90mm strip.

With Lincoln Strip cladding head, you can do both SAW and ESW cladding

Lincoln Cladding head can be used to feed the strip for size 30mm to 60mm

Lincoln Strip cladding head can be used with the pipe of minimum diameter
900mm when the strip reel mounted close the cladding head. The min diameter can
be brought down by locating the reel drum in remote location. But the arrangements
needs to be made by the customer.

When you use ESW (ESSC – Electro slag strip cladding) process, you can
complete the cladding with only one layer, due to its low dilution and high deposition
capability.

In such single layer cladding you can directly use the required alloyed strip to
achieve the required chemistry.

But when you use the SAW process where the dilution rate is high compared to
ESW process, you need to go for multi layer to meet the required chemical
properties.

When you go for multi layer cladding, then for 1st layer you need to use the strip
material i.e. combination of base metal and the required cladd metal and for 2nd
layer you can use the required alloyed strip (cladd metal).

The size of the layer can be adjustable in ESW / SAW process, for each layer you
can achieve a thickness of 3 mm to 5mm based on the welding parameters
(WFS/Amps, Volts & Travel speed).

When you use strips with width over 60mm, then you need to have a magnetic
steering device to control the cladd width. This is required only in ESW process.

But for SAW process, the magnetic steering device is not required to control the
cladd width. Here the cladd width controlled by welding parameters.

Lincoln Electric can support our customers with required welding procedure,
based on your & your client’s requirement.

Lincoln Electric can supply all the required cladding strips from
Lincoln Metrode UK.
 MIS – Sharjah – UAE
 Arabian Industries – Sohar – Oman
 Larsen & Toubro Limited – Sohar – Oman
 Larsen & Toubro Limited – Hazira - India
 Ferro Fab – Dubai – UAE
 Mcdermott – Dubai – UAE
 GAMMOS – Jebel Ali - UAE