Weld Joints Of Clad Material
By L D Poyyara
1
Clad Material
What Is Clad Material / Clad Plate?
Any corrosive ferrous (CS / LAS) base plate which is
integrally bonded with a thin sheet / layer of non
corrosive (SS / non ferrous) material on one side.
Clad Plate
Non Corrosive SS / NFS Clad
CS / LAS Base Material
POYYARA CONSULTANTS 2
Clad Plates
Bonding Process
Clad Bonding by Explosion / Hot Rolling /
Fusion Welding.
Clad Plate
Non Corrosive SS / NFS Clad
CS / LAS Base Material
POYYARA CONSULTANTS 3
Clad Plates
Base Material: CS / LAS
Clad Material:
SS -304, 304 L, 316, 316 L,317, 317 L, 318, 321, 347
NFM / NFA – Copper, Aluminium, Titanium, Monel, Inconel,
Cupronickel
Clad Plate
Non Corrosive SS / NFS Clad CS / LAS Base Material
POYYARA CONSULTANTS 4
Clad Plates
Where Clad Plates are in use?
For Fabricating Pressure Vessels & Pipe
Lines which are subjected to high
pressure & corrosion from inside surface
Pressure Resistant Part
Weld Joint
Clad Restoration
Corrosive
Media
Corrosion Resistant Part
3 to 5 mm thick
POYYARA CONSULTANTS 5
Clad Plates
What is the advantage of using Clad Plates in
Pressure Vessel Fabrication?
Saving in Material Cost. Allows to use low cost CS /
LAS corrosive base material as pressure retaining pats for highly
corrosive fluid. An inside thin layer of non corrosive clad prevents
internal corrosion
Pressure Resistant Part
Weld Joint
Clad Restoration
Corrosive
Media
Corrosion Resistant Part
2 to 5 mm thick
POYYARA CONSULTANTS 6
Clad Plates
What is the disadvantage of using Clad Plates in
Pressure Vessel Fabrication?
Additional Precautions in Fabrication.
Cutting, WEP, Rolling, Handling, Set up, Welding, PWHT
Weld Joint Pressure Resistant Part
Clad Restoration
Corrosive
Media
Corrosion Resistant Part
2 to 5 mm thick
POYYARA CONSULTANTS 7
Cladding By Weld Overlay
What is weld Overlay Clad?
One or more layers of corrosion resistant
weld metal is deposited on CS / LAS base
material
Final Layer – E 308L First Layer - E309
Dilution :- 5 to 8%
ESSC
POYYARA CONSULTANTS 8
Cladding By Weld Overlay
Weld Cladding Process:
ESSC – Electro Slag Strip Cladding. Applicable to large
inside area of Shell, D/E, Cone, & TS
SASC – Submerged Arc Strip Cladding Applicable to large
inside area of Shell, D/E, Cone, TS
FCAW – Flux Cored Arc Welding. Applicable to Flange face,
Small size TS, Pipes of smaller diameter,
MIG – Metal Inert Gas Welding. Applicable to Flange face,
Small size TS, Pipes of smaller diameter,
SMAW – Shielded Metal Arc Welding. Applicable to small
components and repairs of clad
POYYARA CONSULTANTS 9
Cladding By Weld Overlay
Typical Section Of Weld Overlay
Final Layer – E 308L First Layer - E309
Dilution :- 5 to 8%
ESSC
Final Layer – E 308L
First Layer – E 309
Dilution :- 10 to 15%
SASC
POYYARA CONSULTANTS 10
Cladding By Weld Overlay
Typical Section Of Weld Overlay
E308L Final Layer First Layer
E309
Dilution :- 15 to 20%
FCAW / MIG
E308L
Final Layer First Layer
E309
Dilution :- 20 to 25%
SMAW
POYYARA CONSULTANTS 11
What Is Overlap In Weld Overlay?
The extent of covering or over lapping on
previous weld bead by the adjacent bead.
More Thickness
Less Dilution Less Thickness More Dilution
40 to 50 % Over Lap 10 to 15 % Over Lap
POYYARA CONSULTANTS 12
What Is Significant Of Overlap In
Weld Overlay?
Overlap of 40 to 50% in SMAW & FCAW results
in Less Dilution & more weld overlay
Thickness per layer
Less dilution results weld metal chemistry
more towards filler metal chemistry
Less Dilution More Thickness Less Thickness More Dilution
40 to 50 % Over Lap 10 to 15 % Over Lap
POYYARA CONSULTANTS 13
Overlap In ESSC & SASC
The extent of covering or over lapping on
previous weld bead by the adjacent bead.
Minimum Overlay Thickness
Dilution
4 to 5 mm Over Lap
POYYARA CONSULTANTS 14
Weld Joints In Clad Plates
Normally Only Base Metal Thickness Is Considered For
Design Calculations
Base Metal to be welded with qualified WPS
NDT (RT, UT, MT, PT) of weld joint on base metal to be
cleared prior to clad restoration
Clad to be restored by welding (SMAW, FCAW, SAW,
SASC, ESSC) with qualified WPS
Clad Restoration Clad Base Metal
Base Metal Joint
POYYARA CONSULTANTS 15
Typical Butt Weld In Clad Plate
Final Weld Clad Base Metal
3 Base Metal Joint
Clad Restoration – Final Layer
Barrier Layer Clad Base Metal
2 Base Metal Joint
Clad Restoration – Barrier Layer
1 Base Metal Weld Joint
Clad Stripping Clad Base Metal
Base Metal Butt Weld
POYYARA CONSULTANTS 16
Typical Fillet Weld In Clad Plates
SS 304L Support
SS 304L Clad
E308L
3
CS
SS 304L Support
SS 304L Clad
E309
2 CS
SS 304L Support
SS 304L Clad Clad Stripping
1 CS
POYYARA CONSULTANTS 17
Liner Attachment
By L D Poyyara 18
Liner Attachment
What Is Liner Attachment?
A thin sheet / Strip / Pipe of corrosion resistant
material (SS / non ferrous) is attached on corrosive
metal surface by welding along the outer edges.
Unlike clad, Liner is not an integral part of base
material
It is a substitute for Clad
Attachment Weld Liner
CS / LAS Base Material
Vent
POYYARA CONSULTANTS 19
Liner Attachment
Advantages
- Easy to attach
- Cheaper than integral clad / weld overlay
Disadvantages
- Less durable compared to integral clad
- More chances for leakage through liner in service
- Frequent repair / replacement of liner in service
- Needs vent holes below each liner
Attachment Weld Liner
CS / LAS Base Material
Vent
POYYARA CONSULTANTS 20
Typical Liner Attachment Weld
1St Fillet 2nd Fillet
Liner
1 2
Final Layer Liner
3
Attachment Weld Liner
Vent CS / LAS Base Material
POYYARA CONSULTANTS 21
Qualification Requirements For
Weld Joints In Clad Material
By L D Poyyara
22
Welding Qualification For Clad
Material
Generally Qualifications Separately Done For
1) Weld Joints On Base Material
2) Restoration Of Clad On Weld Joints In Base Metal
Base Metal Weld Joint 1
Clad Stripping Clad Base Metal
Base Metal Butt Weld
Final Weld Clad Base Metal
Base Metal Joint 2
Clad Restoration – Final Layer
POYYARA CONSULTANTS 23
Welding Qualification For Clad
Material
Qualifications For Welding Of Base Material
1) Procedure As Per QW 200 & QW 451
2) Performance As Per QW 300 & 452
Test Coupon May Be With or Without Clad
Base Metal Weld Joint
OR
Base Metal Weld Joint
Clad Stripping Clad Base Metal
POYYARA CONSULTANTS 24
Qualification For Weld Overlay / Clad
Restoration
Qualifications For Restoring Clad By Weld Overlay
1) Procedure & Performance As Per QW 217(b), QW 451.4 &
QW 453
Test Coupon may be with or without clad
Base Metal For Welding Qualification – Weld
Overlay / Clad Restoration
Base Metal – Without Cladding
OR
Clad Stripping Clad Base Metal
Base Metal – With Cladding
POYYARA CONSULTANTS 25
Qualification For Weld Overlay / Clad
Restoration
How to qualify procedure?
1 Prepare WPS – Format available in ASME Sec. IX
2 Prepare a test coupon of P number in WPS
3 Coupon may be with or without clad
4 Coupon size minimum 150 mm X 150 mm
5 Coupon thickness minimum equal to production weld,
maximum need not be more than 25 mm
POYYARA CONSULTANTS 26
Qualification For Weld Overlay / Clad
Restoration
Test Coupon For Qualification of Weld
Overlay / Clad Restoration
37 mm min
Base Metal – Without Cladding
OR
Clad Stripping Clad
37 mm min
Base Metal – With Cladding
POYYARA CONSULTANTS 27
Qualification For Weld Overlay / Clad
Restoration
Welding Of procedure Test Coupon
1. Clean the surface
2. Weld barrier layer as per WPS
3. Width minimum 37 mm and length minimum 150 mm
4. PT examine the barrier layer (optional) – Acceptance as
per QW – 195
5. Weld subsequent layers as per WPS
6. PT examine the final layer – Acceptance as per QW –
195
7. Each bead shall have uniform width and height
POYYARA CONSULTANTS 28
Qualification For Weld Overlay / Clad
Restoration
Procedure / Performance Qualification Test Coupon
Weld Area 37 X 150 mm Min
37 mm min Min Job Size – need not > 25 mm
Base Metal – Without Cladding
Barrier Layer OR Final Layer
Clad Stripping 37 mm min Clad
Base Metal – With Cladding
POYYARA CONSULTANTS 29
Procedure Qualification For Weld
Overlay / Clad Restoration
Physical Tests , QW – 453
1. Side Bends - Transverse to welding direction - 4
No, WQ – 161
(Location of bend specimens as per QW – 462.5)
Acceptance Standard, QW - 163
1. No open discontinuity more than 1.5 mm in any
direction within the weld overlay cladding.
2. No open discontinuity more than 3 mm along the
weld interface.
POYYARA CONSULTANTS 30
Procedure Qualification For Weld
Overlay / Clad Restoration
Chemical Analysis. QW – 462.5 (a)
Requires only when WPS / Spec. Calls for
All elements specified in WPS / Spec. are to be
analyzed.
Location of chips based on minimum thickness
of clad / overlay envisaged on production
welds.
Acceptance Limit
Within the WPS / Spec / Clad Chemistry.
POYYARA CONSULTANTS 31
Procedure Qualification For Weld Overlay / Clad Restoration
Location Of Chemical Analysis & Minimum Thickness Qualified
3rd
2nd
1st
Weld inter Face Fusion Face
Base metal
Location of Chips for Chemical Analysis – Depth Minimum Possible
3rd
2nd X X
X 1st
Weld inter Face Fusion Face
Base metal
X = Min. Overlay Thickness Qualified
POYYARA CONSULTANTS 32
Procedure Qualification For Weld
Overlay / Clad Restoration
Special Process Essential Variables. QW –251.4
Welding in each position requires separate
qualification
Welding in vertical up hill position qualifies all
position ( SMAW, GMAW, GTAW).
Welding with single layer and multilayer needs
separate qualification
POYYARA CONSULTANTS 33
Procedure Qualification For Weld
Overlay / Clad Restoration
Procedure Qualification Thickness range – Base
metal & Overlay
Base metal thickness Weld Overlay
Thickness Of Test Qualified Thickness
Coupon
Min Max Min Max
Test Minimum
Less Than 25 mm Coupon Any thickness
Thickness where
chemical Any
analysis
Above 25 mm 25 mm Any found
within limit
POYYARA CONSULTANTS 34
Performance Qualification For Weld
Overlay / Clad Restoration
How to qualify Welders Performance? QW-381
1 Prepare WPS & Qualify the procedure
2 Prepare a test coupon of P number in WPS
3 Coupon may be with or without clad
4 Coupon size minimum 150 mm X 150 mm
5 Coupon thickness minimum equal to production weld,
maximum need not be more than 25 mm
POYYARA CONSULTANTS 35
Qualification For Weld Overlay / Clad
Restoration
Welding Of Performance Test Coupon
1. Clean the surface
2. Weld barrier layer as per WPS
3. Minimum three beads in first layer
4. Width minimum 37 mm and length minimum 150 mm
5. PT examine the barrier layer (optional) – Acceptance as
per QW – 195
6. Weld subsequent layers as per WPS
7. PT examine the final layer – Acceptance as per QW –
195
8. Each bead shall have uniform width and height
POYYARA CONSULTANTS 36
Procedure Qualification For Weld
Overlay / Clad Restoration
Physical Tests , QW – 453
Side Bends - Transverse to welding direction - 4
No, WQ – 161
(Location of bend specimens as per QW – 462.5)
Acceptance Standard, QW - 163
No open discontinuity more than 1.5 mm in any
direction within the weld overlay cladding.
No open discontinuity more than 3 mm along the
weld interface.
POYYARA CONSULTANTS 37
Performance Qualification For Weld
Overlay / Clad Restoration
Applicable Essential variables QW – 350 & 360
No upper limit for thickness of overlay qualified
Welders qualified on Clad restoration or liner
attachment are also qualified in weld overlays
QW – 381 (d)
No limits in pipe diameters, if welded in
longitudinal direction QW – 381 (c)
POYYARA CONSULTANTS 38
Performance Qualification For Weld
Overlay / Clad Restoration
Performance Qualification Thickness range – Base
metal & Overlay
Base metal thickness Weld Overlay
Thickness Of Test Qualified Thickness
Coupon
Min Max Min Max
Test
Less Than 25 mm Coupon Any
Thickness
Procedure
Any
Qualified
Above 25 mm 25 mm Any
POYYARA CONSULTANTS 39
Liner Attachment
Qualification Requirements for Liner Attachment
procedure :- WPS qualified on Groove / Fillet as
per QW – 202.2 (a), (b) or (c) also
qualifies for liner attachments within
the essential variables, If chemical
analysis is not a requirement
Performance:- Welders those who are qualified for
groove / fillet welds as per QW 301 are
also qualified for liner attachments
within the essential variables
Attachment Weld Liner
CS / LAS Base Material
Vent
POYYARA CONSULTANTS 40
Liner Attachment
Alternate Qualification. QW – 218.2, QW - 383.2 (b)
procedure & Performance
- Weld a liner attachment assembly as shown below as per
the WPS.
- Base plate thickness min. job size max. need not be more
than 25 mm
- One Cross Section from each position for macro exam
- Chemical analysis if required as per WPS only for
procedure
- Each position needs separate qualification
- Procedure in vertical up qualifies all position
Final Layer Liner
POYYARA CONSULTANTS 41
Precautions in Fabrication of Clad vessel
Storage & Handling
Do not walk on clad plates
Do not keep ferrous material in contact with clad
plates.
While clamping for lifting, rubber/wooden packing
shall be provided on clad side
while storing, keep plates vertically on plate racks.
Keep clad side always cleaned.
Keep plates on wooden sleepers if clad side facing
down
POYYARA CONSULTANTS 42
Precautions in Fabrication of Clad vessel
Cutting
Cutting can be done by oxy acetylene flame
Remove 10 mm wide clad from opposite side before
cutting.
Removal of clad shall be by careful grinding.
Do not reduce base metal thickness while grinding the
clad.
Cutting shall be done from Base metal side.
Slag/iron oxide shall not come in contact with clad.
POYYARA CONSULTANTS 43
Precautions in Fabrication of Clad vessel
Wed Edge Preparation
WEP can be prepared by gas cutting or by machining
Clad shall be removed from the WEP by 6 to 9 mm wide
Clad removal shall be by careful grinding / machining
Total removal of clad material from surface to be
confirmed by coppersulphate solution
Base metal thickness shall not be reduced while grinding
While grinding, the operator shall sit on clad side with a
ply wood / plastic sheet. Do not step / walk on clad side
POYYARA CONSULTANTS 44
Precautions in Fabrication of Clad vessel
Set up
Do not weld temporary clits or supports on clad side.
Do not strike arc on clad side
Temporary clits and supports shall be from base metal
side only.
All tacks shall be within the groove of base material
Only qualified welders shall make tacks. Tacks shall be
free from defects.
Preheating wherever required shall be on Base metal
side
POYYARA CONSULTANTS 45
Precautions in Fabrication of Clad vessel
Welding of CS / LAS base material
Only qualified welders shall make the weld.
Apply lime powder paste on either side of WEP for 150
mm wide. This is to eliminate spatters sticking to clad
surface
Do not strike arc on clad material. No welding of CS / LAS
shall come in contact with clad metal
If preheat is applicable, heat from base metal side.
While welding from clad side, welder shall use ply wood or
plastic sheet to sit on.
Welding of Base metal shall be completed, ground smooth,
PT checked and radiographed.
POYYARA CONSULTANTS 46
Precautions in Fabrication of Clad vessel
Welding of clad or clad restoration
Only weld overlay qualified welders shall make the weld.
Welding consumable and parameters shall be as per WPS
Apply lime powder paste on either side of WEP for 150 mm wide.
This is to eliminate spatters sticking to clad surface
Clear RT and PT of base metal weld prior to clad restoration
Do not strike arc on clad material.
If preheat is applicable heat from base metal side.
While welding from clad side, welder shall use ply wood or plastic
sheet to sit on.
Clear PT examination on barrier layer final layer of weld.
POYYARA CONSULTANTS 47
Thank You
48
