Comprehensive Strip Cladding Guide

Have you ever heard of strip cladding? If you think it is something very complicated and fancy, it’s not. It is basically a welding technique where you fuse one layer of metal to cover the surface of another material.

This technique is widely used to restore and enhance the durability and appearance of different materials. The most suitable materials used for strip cladding are the ones which are not only water-resistant but also corrosion-resistant.

This technique helps improve the strength and longevity of metals. There are different applications of the process in industries, including processing of chemicals, oil & gas, petrochemical, and power generation, since materials are exposed to extreme temperature and pressure conditions in these industries.

You cannot confuse it with coating a metallic layer. A firm metallurgic bond is formed between the cladding and the base metal during this process.

So, it’s essential to learn about the process if you’re in the field. We will explain everything regarding strip cladding, its types, applications, process, benefits, maintenance tips, and so much more.

What is Strip Cladding?

Strip Cladding

It is a surface-enhancing technique based on welding to restore and protect different industrial components.

It involves depositing a continuous, thin metallic layer made of corrosion-resistant alloy on a base metal to form a firm bond. This technique is quite common in industries where there is a lot of heat and pressure exposure.

The equipment and machinery used in such environments are more susceptible to damage and corrosion. So strip cladding protects them from excessive damage.

Strip cladding is different from traditional cladding methods where there is no metallurgical bond involved and is based on metal adhesion. In this method, you have to fuse the strip cladding with the base metal directly.

Since there is a permanent fusion, it eliminates all the risks of peeling and delamination. The most common reason to use this technique is to upgrade the quality of low-cost materials to make sure the structural integrity is maintained in the industrial setting without needing to replace them with costly ones.

There are different materials used as strip cladding materials, such as nickel alloys, cobalt-based alloys, and stainless steel, according to certain operating environments. There are different factors that affect the selection of these metals, including mechanical stress, exposure to chemicals, and temperature resistance.

The right selection makes sure the finished surface meets perfectly to required standards.

Different Types of Strip Cladding

There are different types of strip cladding based on two factors: the material used and the welding method employed. Material selection is done based on the level of protection needed, the project’s industry, and the environment.

Some of the most common strip cladding types are discussed below:

1. Stainless Steel Strip Cladding

The most frequently used material in strip cladding is stainless steel. Why? Stainless steel is resistant to corrosion and has high temperature tolerance. Most of its applications are on carbon steel, and it helps minimize oxidation and keeps rust at bay.

Stainless steel strip cladding is widely used in industries like marine application, food processing, and chemical processing.

Stainless steel has chromium content in it, which increases its chemical resistance properties. Besides, it also boosts the material’s ability to tolerate extreme temperatures.

These properties extend the service life of base materials.

2. Nickel-Based Alloy Strip Cladding

Monel and inconel are the two nickel-based alloys that have superb resistance against overly aggressive environmental conditions, extreme temperatures, and acidic environments.

Different industries, such as petrochemical plants, power generation, and offshore drilling, use nickel-based alloys. These industries deal with seawater, excessive heat, and sulfuric acid, all of which can damage the metals to a greater degree.

Nickel-based alloys are much stronger and have multiple mechanical properties. They are well-suited for turbines and reactor vessels because they handle high stress quite effectively.

3. Cobalt-Based Alloy Strip Cladding

Cobalt-based alloys have amazing anti-wear properties. One such example is Stellite.

Cobalt-based alloys offer greater hardness and abrasion resistance properties to the components operating at high-friction conditions, such as cutting tools, valve seats, and bearings. These alloys not only withstand extreme friction but also high temperatures. So, it makes an ideal deal for those industries where there are a lot of chances of wear and high temperature.

4. Titanium Strip Cladding

This metal has an exceptional strength-to-weight ratio and is highly resistant to corrosion.

Titanium performs particularly well under chloride exposure like chemical plants and seawater. This type of strip cladding has various applications in aerospace components, pressure vessels, and heat exchangers because they need less weight and greater durability.

The application is not limited to these industries only. Titanium strip cladding is a preferred choice for food processing and pharmaceuticals as well since they require minimal material contamination.

5. Copper & Copper Alloy Strip Cladding

Brass and bronze are daily routine copper alloys and have wide applications in dozens of industries. Their thermal and electrical conductivity and antimicrobial properties make them distinct from other alloys.

That is why the health care sector, electronics, and power transmissions use copper and its alloys for strip cladding.

Types Based on Welding Variations

As mentioned earlier, there are different types of strip cladding based on welding techniques, too. This aspect is important as strong permanent bonds are created through these welding techniques to accomplish desired properties and efficiency.

So, based on welding techniques, the following are the types:

Reasons Why Strip Cladding is Used?

There are different benefits of strip cladding, from providing durability to extended lifespan of the metallic components.

A high-performance, solid metal, once deposited on weaker materials, not only enhances their appearance but offers numerous good properties. Below are the five most important reasons why industries use strip cladding.

1. Improved Resistance to Corrosion

The industrial environment is full of toxic chemicals, moisture, seawater, high temperature and pressure, and harsh weather conditions. When metallic equipment, machinery, and other components are exposed to these conditions for a longer period of time, they start deteriorating.

Through strip cladding, a protective and stronger layer is deposited on these components and machinery to prevent their surfaces from oxidation, corrosion, and degradation due to chemicals.\

Nickel-based alloys and stainless steel strip cladding are ideal for alkaline and acidic conditions, so marine industries and chemical processing units mainly use it.

2. Protection From Wear & Abrasion

Strip cladding is a perfect way to protect metallic components from abrasion, friction, and wear and tear in conditions where there is a lot of high friction and high stress involved.

Strip cladding adds a high-strength protective layer over the weaker surfaces that are resistant to wear. Satellite is frequently used for this purpose because it has exceptional anti-wear and durability properties and makes sure the structural integrity of the components remains good under extreme conditions.

3. Affordable Than Solid Alloy Component

Strip cladding is quite an affordable option as an alternative to replacing an entire component that’s damaged and is very expensive to replace.

Manufacturers and industries usually opt for strip cladding and cut the cost of replacing an entire chunk of base metal that’s expensive. They only coat the surface with high-strength strip cladding.

It helps manufacturers and industries renew surfaces while staying in budget and also reducing raw material wastage. However, this does not mean that the quality is compromised. Strip cladding gives an optimum finish and quality.

4. Resistance Against Temperature & Heat

Industrial settings involve extreme heat and temperature situations that damage the surface and structure of metallic components over time.

Titanium and Inconel strip claddings are effective in this case as they are heat resistant and help protect them against thermal damage.

So, strip cladding is especially important for oil and gas, power plants, and aerospace industries because their machinery and equipment are constantly exposed to high temperatures.

5. Increase Lifespan

Another benefit of strip cladding is its ability to extend the service life of components by reducing wear and structural degradation. When a protective deposition is present over the surface of the base metal, it will need less maintenance and repairing, leading to reduced downtime and improved efficiency.

6. Strong Metallurgical Bond

Traditional coatings peel and chip off after some time when exposed to moisture and environmental conditions. That is not the case with strip cladding.

It is done through welding a strip layer with a base metal and forming a permanent metallurgical bond. This bond is firm and doesn’t chip off with time.

Strip cladding bond makes sure the renewed component withstands all the stress conditions without any damage.

Strip Cladding Applications

There are multiple applications of strip cladding in various industries, as mentioned in previous sections. We will briefly discuss these industries and the strip cladding applications in them.

• Oil and Gas

The equipment is continuously exposed to corrosion and temperature, making strip cladding an absolute fix. It is used in pipelines, drilling equipment, pressure vessels, and storage tanks.

• Power Generation

This industry works under extreme temperatures and is exposed to harsh chemicals, requiring strip cladding to play its part and protect against heat and chemical degradation. The process has applications in turbine blades and rotors, boilers, nuclear reactor components, and heat exchangers.

• Chemical and Petrochemical

Metallic surfaces deteriorate with time in chemical plants as they are under constant exposure to reactive and corrosive chemicals. Strip cladding is used to protect pumps, valves, storage tanks, reactors, transport containers, and distillation columns.

• Marine and Offshore

Saltwater increases the corrosion effect even more than normal water. So, in marine and offshore structures, there are more chances of corrosion of metals compared to other industrial settings.

Strip cladding is used for decks, ship hulls, subsea pipelines, and offshore oil platforms.

Besides these, strip cladding is involved in aerospace and defence and mining and heavy machinery as well.

Process of Strip Cladding

Strip Welding in Process

Strip cladding involves deposition of cladding layer to the base material through a certain welding technique. A strong metallurgical bond is formed as a result of this welding, providing reliability and efficiency. Here’s how it’s done in different steps:

Preparation

Clean the surface of the base material and remove all the dust, debris, contaminants, and grease that may weaken the welding process.

Some metals need to be preheated to improve thermal conductivity, so if you are dealing with such a metal, preheat it.

Position the base material appropriately and make sure the surface is even for uniform strip cladding.

Select Cladding Material

Choose an appropriate material based on your requirements. The common materials are titanium, stainless steel, nickel based alloys, cobalt-base alloys, and copper.

Check the compatibility of the cladding material and the base metal to ensure they fuse together well.

Keep the environmental factors and set certain parameters like pressure, chemical exposure, and temperature.

Cladding Layer Deposition

Select the welding technique required, and as soon as you start welding, the strip metal will begin melting and start forming a thin layer on the base material surface.

Keep an eye on the heat input, welding speed, and shielding gases for efficient welding. Do multiple passes to get the desired thickness.

Post-Cladding Treatments

Once you are done with the welding, let the surface cool down. After that, smooth out any irregular bumpy area by grinding.

It is recommended to perform annealing or stress relieving to enhance mechanical properties. Finally, inspect through non-destructive testing.

Conclusion

Strip cladding is basically a welding technique where a cladding layer is deposited on the base material through fusion.

It enhances durability, reduces corrosion and wear, increases the longevity of the materials, decreases maintenance cost, and makes the material as good as new.

There are different applications of strip cladding in various industries, including oil and gas, aerospace, petrochemical and chemical processing, marine, offshore structures, machinery, and others.

The most commonly used metals for strip cladding are stainless steel, titanium, nickel alloys, cobalt alloys, and copper alloys.