Weld Overlay Thickness Calculator
An engineering tool to estimate the minimum required thickness for a corrosion-resistant weld overlay (cladding) based on the specified corrosion allowance.
What is Weld Overlay / Cladding?
Weld overlay, also known as cladding or hardfacing, is a process where a layer of a more durable or corrosion-resistant material is welded onto the surface of a less-resistant base material. This is often more economical than making the entire component out of the expensive, high-performance alloy. It's commonly used in pressure vessels, chemical processing equipment, and components subject to high wear.
The Challenge of Dilution
The main challenge in weld overlay is **dilution**. When the cladding material is welded onto the base metal, some of the base metal melts and mixes with the first layer of cladding, diluting its properties. For example, if you are cladding carbon steel with stainless steel, the first layer will pick up carbon from the base metal, reducing its corrosion resistance. To achieve the full properties of the cladding material on the surface, a second or even third layer is often required.