Weld Overlay Calculator
Calculate cladding thickness, dilution, and layer requirements.
Typical Dilution by Process
| Process | Dilution | Deposition Rate |
|---|---|---|
| SAW Strip (60mm) | 8-12% | Very High |
| SAW Wire | 25-40% | High |
| ESW Strip | 5-10% | Very High |
| GMAW (Pulse) | 15-25% | Medium |
| GTAW Hot Wire | 5-15% | Low |
| GTAW Cold Wire | 3-8% | Very Low |
Weld Overlay Principles
Why Overlay?
- Corrosion Resistance: Apply CRA to carbon steel for corrosive service
- Wear Resistance: Hardfacing extends service life
- Dimensional Restoration: Rebuild worn components
- Transition Layer: Buttering for dissimilar metal joints
Dilution Considerations
- First Layer: Highest dilution from base metal - may not meet chemistry
- Second Layer: Diluted from first layer - usually meets minimum chemistry
- CRO Specification: Often requires <10% Fe at surface for corrosion resistance
Quality Requirements
- Chemistry: Verify final surface meets specification via PMI or chemistry
- Bonding: Ensure good fusion without defects at interface
- Hardness: Check hardness traverse for hardfacing applications
- NDE: PT/MT for surface defects, UT for disbonding