Double Tungsten Hot-Wire TIG Cladding Process

Components in critical industries like oil & gas, chemical processing, power generation, and nuclear often require exceptional resistance to corrosion, wear, and high temperatures. While various cladding methods exist, the double tungsten hot wire TIG (Gas Tungsten Arc Welding) cladding process stands out as a highly specialized and precise technique for depositing high-performance alloy overlays.

At FNS Pipeline, we leverage the unparalleled control and metallurgical integrity of double tungsten hot wire TIG cladding to extend the lifespan and enhance the reliability of your most vital components.

Double Tungsten Hot-Wire TIG Cladding Process

Understanding the Precision of Hot Wire TIG Cladding

TIG cladding uses a non-consumable tungsten electrode to create an arc, melting the base material while a separate filler wire is introduced into the weld pool. The use of an inert shielding gas protects the weld from atmospheric contamination, resulting in extremely clean and sound deposits.

The “Hot Wire” enhancement takes TIG cladding a step further:

Pre-heating the Filler Wire: In hot wire TIG, the filler wire is independently preheated (resistively) to its melting point before it enters the weld pool. This preheating significantly reduces the amount of arc energy required to melt the filler material.

Benefits of Hot Wire: This leads to a substantial increase in deposition rate, meaning more material can be applied per unit time. At the same time, it reduces heat input to the base material and achieves extremely low dilution with the substrate.

The Advanced Edge: Double Tungsten Hot Wire TIG Cladding by FNS Pipeline

FNS Pipeline elevates the Hot Wire TIG process by utilizing a Double Tungsten configuration. This specialized setup offers enhanced stability, control, and efficiency, allowing us to achieve superior clad quality for even the most challenging applications.

How Our Double Tungsten Hot Wire TIG Cladding Works:

1.Precisely Prepared Substrate: The component surface is meticulously cleaned and prepared to ensure optimal metallurgical bonding.

2.Primary TIG Arc (Main Tungsten Electrode): A conventional TIG arc is established using the primary tungsten electrode. This arc provides the localized heat to create a small, precisely controlled melt pool on the base material’s surface.

3.Secondary Hot Wire Feeding System (with Heated Filler Wire): Simultaneously, a precisely controlled feed system introduces the filler wire (e.g., Inconel, Stainless Steel, Hastelloy) into the melt pool. Crucially, this filler wire is resistively heated by a secondary power source before it reaches the arc.

4.Double Tungsten Control: While the exact configuration can vary, “Double Tungsten” typically refers to the use of two tungsten electrodes or a highly sophisticated dual-torch system. This allows for:

• Enhanced Arc Stability: Providing greater control over the melt pool.
• Wider Bead Coverage: Potentially allowing for broader clad beads per pass.

Optimized Heat Distribution: More precise management of heat input into both the substrate and the filler wire.

5.Inert Gas Shielding: A continuous flow of high-purity inert gas (e.g., Argon) surrounds the weld pool, protecting it from oxidation and atmospheric contamination, ensuring a pristine metallurgical bond.

6.Automated Control: The entire process is meticulously controlled by advanced automation systems, managing arc parameters, wire feed speed, preheat temperature, travel speed, and oscillation for uniform and repeatable results.

Key Applications of Double Tungsten Hot Wire TIG Cladding

The unique advantages of FNS Pipeline’s Double Tungsten Hot Wire TIG cladding process make it the preferred choice for critical components across various industries:

Oil & Gas Industry:
Pressure Vessel Nozzles & Internals: Cladding of inlets, outlets, and internal surfaces with Inconel or Stainless Steel for corrosion and sour gas resistance.

Subsea Components: Protection against highly corrosive seawater and internal media.

Clad Pipes & Fittings: Manufacturing or reconditioning pipe spools and fittings for CRA service.

Chemical & Petrochemical Processing:

Reactor Vessels & Columns: Internal cladding for resistance to aggressive chemical attack.

Heat Exchanger Components: Tubesheets and channels requiring specialized corrosion resistance.

Power Generation:

Boiler Tubes: Protection against corrosion and erosion in demanding boiler environments.
Turbine Components: Enhancing lifespan in high-temperature sections.

Nuclear Industry:

Components requiring very low dilution and high integrity for safety-critical applications.

Marine Industry:

Propeller shafts and other components exposed to corrosive seawater.

Any Component Requiring CRA Overlay: Where the integrity and properties of the clad layer are paramount, and dilution must be strictly controlled.

The FNS Pipeline Advantage: Expertise in Precision Cladding

At FNS Pipeline, we combine state-of-the-art Double Tungsten Hot Wire TIG cladding equipment with a team of highly skilled engineers and certified welding specialists. Our deep understanding of metallurgy, material science, and automation allows us to deliver:

• Unrivaled Quality: Consistently producing overlays with minimal dilution, superior bonding, and zero defects.
• Customized Solutions: Tailoring cladding parameters and material selection to meet the precise demands of your application.
• Adherence to Standards: Our processes are compliant with international quality and industry standards (e.g., ISO, ASME, API), ensuring reliability and traceability.
• Extended Component Lifespan: Protecting your investments by vastly increasing the durability and operational life of your critical assets.

Don’t compromise on the integrity of your critical components. Invest in the precision and performance of FNS Pipeline’s Double Tungsten Hot Wire TIG Cladding Process.

Contact FNS Pipeline today for a technical consultation or to request a detailed quote for your specialized overlay cladding requirements.