Multi-Pass Dilution Chemistry Calculator

Calculate cumulative dilution and weld metal chemistry across multiple passes accounting for remelting of previous passes

Input Parameters

Results

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Pass 1 Dilution
%
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Final Surface Dilution
%
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Surface Ni Content
wt%
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Min Passes for <5% Dilution
Note: Critical for corrosion-resistant weld overlays (CRA cladding). ASME and NACE require minimum chemistry at the surface after final pass. Nickel alloy overlays typically need 2-3 layers to meet corrosion requirements.

Reference

Multi-Pass Dilution Model: Pass 1 dilution: D1 (from base metal, typically 20-50%) Pass n surface dilution: D1 x R^(n-1) R = remelt fraction of previous pass (typically 15-25%) Surface chemistry: X_surface = D_final x X_base + (1-D_final) x X_filler For overlay/cladding: minimum 2-3 passes to achieve <5% base dilution