Cladding low alloy carbon steel with stainless steel using SAW wire process.

Good afternoon. I would like to get some input from the welding community with regards to cladding
stainless steel onto a carbon steel substrate. My company has in the past performed this kind of cladding
process however I see that there is a constant problem with the achieving the correct clad layer chemistry.
In response to this, I requested that we try to change the process from DCEP to DCEN as well as use an
active flux (containing alloying elements) instead of a neutral flux to prevent such heavy losses of
chromium to the slag.
Before I give the final go ahead for trial runs, I would like to find out if anyone has got experience in this
process and if there are any recommendations? I would especially appreciate recommendations on the
amount of overlap and if it would be possible for this process to succeed with only one layer. The
consumable used to clad with is a 308L wire.
Krishna Sampath I would refer you to strip cladding using SAW, and not wire. Why use wire when strip
cladding was commercialized nearly 50 years ago. You may want to review literature from Nickel
Development Institute. Electrolsag strip cladding is even better. Oregon Graduate Institute could possibly
help you with the latter, if strips of suitable chemical compositions are commercially available.
Alan Mayfield DC- will definitely reduce dilution if you use a longer stick out. Depending on the
application using 309L may be more successful if you need to weld it in one layer. 309L is really designed
for this but of course the weld will contain Mo.
The overlap depends on the speeds etc and if you are oscillating, in which case you will also need a
dwell.
Brent Sellers Kristian,
Many customer specifications do not permit active flux. As Alan mentioned DCEN will reduce dilution
however; I suspect the weld to be very sluggish and struggle to tie in (voltage & overlap will be critical).
50-60% overlap is standard for first layer SAW overlay however; I have only qualified DCEP & AC SAW
overlay procedures. Investigate how travel speed, wire size, voltage, heat input, & overlap effect
weldability & dilution. Lots of ways to skin a cat... find a method your shop can repeat.

Pierre Gerard dear Kristian, it depends on the shape of the component you want to clad but i would also
advice the use of the ESW process. you can easily reach the asme 308l chemistry in a single layer of
5mm.
Kristian Kruger Thank you very much for all the input. I will definately have a look at the client
requirements with regards to active fluxes and will play around with the parameters until I get a decent
clad.

Unfortunately, I cannot change the process to strip cladding (I did look into it) because my budget will not
allow it.
Richard Holdren Kristian, Brent probably has the best suggestions. In my experience, step-over (or bead
overlap) on the first layer is the most critical factor. On first layer, reduce heat input and use a small stepover. On second layer, you can increase heat input and step-over distance. Chromium-compensating
fluxes will also help to achieve desirable FN. For more details, check out the work we've done
at www.arcspecialties.com\technical services\white papers. There are a number of presentations there,
including a study looking at the effects of different fluxes. Brent was correct in that DCEN will reduce
dillution; however, arc stability and bead tie-in will suffer.
Ramesh Singh If possible, (weld Geometry) I will start with manual first layer of DCEN suitable E 309,
then follow with SAW as said above the experience shows that weld pool is very sluggish and keeping a
50+% over lap of beads is essential for subsequent passes. Best way is to weld some coupons and test
them and thus finalize welding procedure that suits your work, given that there would be number of other
factors working.
Mark Mruczek You have received a lot of good advice here for SAW. The only process that I have seen to
achieve or meet chemistry requirements in one layer during clad welding is the Fronius CMT process.
However most clients that I am aware of require two layers. Unfortunate, because this is a great process.
You could still use the processes but with two layers. This process would alleviate the concerns for
meeting your chemistry requirements and deposition rates would be close to the SAW process and you
eliminate Flux since this is a GMAW process.
Howard Record Kristian, You might want to look at ESW strip cladding. This process has very low
dilution and with the right flux/strip combo you can achieve proper chemistry on one pass. Strip cladding
will also speed up the process due to using a 60mm wide strip vs a sub arc wire. You can use all of your
original sub-arc equipment and just add a strip cladding head. Look at the videos of this process
on www.rtdtools.com.