Weld Joints Of Clad Material

By L D Poyyara

1
 Clad Material
What Is Clad Material / Clad Plate?
Any 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 of
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 towardsMorefiller metal chemistry
Thickness
Less Dilution Less Thickness More Dilution

40 to 50 % Over Lap 10 to 15 % Over Lap

POYYARA CONSULTANTS 13
 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, ASW,
SASC, ESSC) with qualified WPS

Clad Restoration Clad Base Metal

Base Metal Joint

POYYARA CONSULTANTS 14
 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 15
 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 16
Liner Attachment

By L D Poyyara 17
 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 18
 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 19
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 20
Qualification Requirements For
Weld Joints In Clad Material
By L D Poyyara

21
 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 22
 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 23
 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 24
 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 25
 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 26
 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 27
 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 28
 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 29
 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 30
 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 31
 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, SAW, GMAW, GTAW).

Welding with single layer and multilayer needs

separate qualification
POYYARA CONSULTANTS 32
 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 33
 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 34
 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 35
 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 36
 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 37
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 38
 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 39
 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 40
Thank You