weldtech talk

The video “Duplex Stainless Steel – Opportunities and Challenges” features a detailed technical talk by Mr. Sukamal Naskar, presented as part of a webinar organized by the Indian Institute of Welding, Mumbai Branch on duplex stainless steel welding and its industrial relevance. The session explains what duplex stainless steels are — alloys that combine austenitic and ferritic microstructures — and why they are increasingly used in demanding environments like oil & gas, chemical processing, and marine applications due to their high strength and excellent corrosion resistance. The talk provides context on how these materials fit into modern engineering projects and why understanding their behaviour is important for materials and welding professionals.

Mr. Naskar also discusses the challenges associated with welding and fabricating duplex stainless steels, particularly the need to maintain the correct balance of phases and control heat input during welding to avoid detrimental microstructures that can weaken corrosion resistance and mechanical properties. He emphasizes practical considerations in welding parameters, consumable selection, and heat management to ensure that the advantages of duplex steels — such as strength and performance in corrosive environments — are fully realized in fabricated components.

Is Welding Nickel Alloys Difficult or Different?

This insightful technical session begins with Mr. Samuel Kiser, who explains that welding nickel alloys is not necessarily difficult, but it is different compared to carbon or stainless steels. He discusses how nickel alloys behave uniquely under heat, requiring careful control of heat input, cleanliness, and filler metal selection. Mr. Kiser shares practical tips and tricks, emphasizing that proper preparation, contamination control, and understanding metallurgical characteristics are key to achieving sound welds and preventing common issues such as cracking or porosity.

In the second section, Mr. Brian Gaal covers the important topics of joining and cladding of nickel alloys, explaining how these materials are effectively used in demanding environments where corrosion and high temperatures are critical concerns. He highlights procedures, welding techniques, and considerations for maintaining weld integrity. Finally, Mr. Lew Shoemaker discusses corrosion testing and the application of nickel alloys in Flue Gas Desulfurization (FGD) systems, demonstrating how these alloys perform in highly corrosive industrial conditions. Together, the speakers provide a comprehensive understanding of nickel alloy welding, performance, and real-world industrial applications.

The video features a technical presentation by Mr. Pradip Goswami, a welding and metallurgical expert, on the practical aspects of welding CSEF (Creep Strength Enhanced Ferritic) Grade 91 steels. He explains that Grade 91 steel is widely used in high-temperature and high-pressure applications such as power plants due to its excellent creep strength, but it is highly sensitive during welding. Mr. Goswami emphasizes the importance of following qualified welding procedures, proper material handling, and strict control of consumables to avoid weld defects and ensure long-term reliability.

A major focus of Mr. Goswami’s discussion is temperature control, including proper preheating, maintaining correct interpass temperatures, and carrying out accurate post-weld heat treatment (PWHT). He highlights that failure to manage these parameters can result in hydrogen cracking, excessive hardness, and long-term failures such as Type IV cracking in the heat-affected zone. Overall, he stresses that welding Grade 91 steel requires strong metallurgical understanding and disciplined execution to ensure safe and durable service performance

The webinar was organized by the Indian Institute of Welding (IW India), Mumbai Branch, with a strong focus on advancing welding technology and skill development in India. IW India continues to play a key role in promoting human resource development, research and development, adherence to international standards, and professional training and certification across the country. The session featured distinguished international experts from TWI (The Welding Institute), UK — Mr. Chris Wiseman, a materials scientist, and Mr. James Redman, a specialist in diffusion bonding technology — who shared their technical expertise and global experience.

The speakers provided an in-depth overview of diffusion bonding, a high-precision solid-state joining process that uses controlled heat and pressure to join complex and difficult-to-weld materials. The technique is widely used in the production of compact heat exchangers for aerospace, automotive, and petrochemical industries, and is particularly valuable in applications requiring lightweight, high-strength, and corrosion-resistant structures. Special attention was given to aluminum diffusion bonding, which presents challenges due to persistent oxide layers, and how TWI has developed proprietary solutions to overcome these limitations without the need for interlayers. The session also highlighted TWI’s collaboration with Indian industry, including training initiatives and technology transfer in areas such as additive manufacturing. Emphasis was placed on surface preparation, process parameter control, and quality assurance as critical factors for successful outcomes. The webinar concluded with an interactive Q&A session, underscoring future collaboration opportunities between IW India and TWI to further strengthen welding innovation in India.

Why Are Weldments More Prone to Corrosion and How Can It Be Prevented?

This webinar by the Indian Institute of Welding (IW India), Mumbai Branch explains why welded joints are more susceptible to corrosion than base metals. Unlike parent materials produced under controlled conditions, weldments contain fusion zones, heat-affected zones (HAZ), chemical variations, and residual stresses that increase corrosion risk. The session covers key corrosion mechanisms such as preferential weld corrosion, sensitization, secondary phase formation, heat tint effects, and various types of stress corrosion cracking (SCC), emphasizing how welding parameters and environmental exposure directly influence long-term performance.

The speaker highlights that corrosion resistance cannot be assured through mechanical testing alone and stresses the importance of corrosion qualification testing using relevant ASTM and NACE standards. Best practices include using matching consumables, controlling heat input and cooling rates, maintaining cleanliness, minimizing residual stresses, and applying appropriate post-weld treatments like pickling and passivation. Overall, the session reinforces that proper metallurgical understanding and disciplined welding procedures are essential to prevent corrosion-related failures in service.

What Makes Aluminium Welding Challenging and How Can It Be Effectively Managed?

This webinar organized by the Indian Institute of Welding (IW India) highlights the institute’s role in advancing welding education, certification, research, and industry collaboration across India. As a member of the International Institute of Welding (IIW), IW India promotes skill development, technology transfer, and adherence to international standards. The technical session focused on aluminium welding, a subject of growing importance due to aluminium’s increasing use in automotive, aerospace, railways, defense, and EV industries for its lightweight and corrosion-resistant properties.

The presentation explained that aluminium welding is technically demanding because of its low melting point, high thermal conductivity, high thermal expansion, and the presence of a strong oxide layer that must be properly managed during welding. Challenges such as distortion, hot cracking, and porosity were discussed, along with the importance of surface preparation, proper shielding gas control, correct filler selection, and heat input management. Advanced techniques like friction stir welding and other solid-state processes were also highlighted as effective solutions. Overall, the session emphasized that with proper process control and metallurgical understanding, aluminium welding can be performed successfully and reliably.

The webinar “Advanced Welding Practices and Metallurgical Considerations”, organized by the Indian Institute of Welding (IW India), Mumbai Branch, discusses the critical role of metallurgy and process control in achieving high-quality welds. The session explains how material behavior, heat input, and welding parameters directly affect the weld metal and heat-affected zone (HAZ), influencing overall structural integrity and service performance.

The speaker also highlights practical fabrication challenges such as defect prevention, residual stress control, and quality assurance. Emphasis is placed on proper procedure qualification, correct consumable selection, and adherence to industry standards. Overall, the webinar reinforces that successful welding depends on strong technical knowledge combined with disciplined execution in real-world applications.

What Are the Key Challenges and Best Practices in Aluminium Welding?

This webinar provides a comprehensive overview of aluminium welding, explaining why aluminium’s growing use in transportation, aerospace, marine, and cryogenic applications demands specialized welding knowledge. Aluminium’s low weight, good corrosion resistance, high thermal and electrical conductivity, and wide strength range make it highly attractive industrially. However, these same properties create welding challenges, including rapid heat dissipation, oxide layer formation, strength reduction in the heat-affected zone (HAZ), and sensitivity to alloy chemistry. Understanding alloy classifications, strengthening mechanisms, and proper filler selection is essential to achieving reliable weld performance.

The session highlights two major discontinuities in aluminium welding: porosity and hot cracking. Porosity mainly results from hydrogen contamination due to moisture or improper cleaning, making strict surface preparation and shielding gas control critical. Hot cracking, on the other hand, is strongly influenced by alloy chemistry and weld metal composition, and can be mitigated through correct filler alloy selection and appropriate joint design to control dilution. The webinar emphasizes that aluminium welding requires a “hot and fast” technique with controlled heat input, careful material handling, and adherence to relevant codes and technical references to ensure quality and durability in service.

This webinar by the Nickel Institute featured Dr. Graham Sussex, corrosion and materials consultant, who delivered a comprehensive session on stainless steel welding, quality control, and corrosion performance. The presentation began with an overview of nickel’s critical role in stainless steel, where it enhances strength, ductility, and performance in extreme temperatures and aggressive environments. Different stainless steel families—including austenitic, ferritic, duplex, and martensitic grades—were discussed, along with the importance of alloying elements such as chromium, molybdenum, and nitrogen in determining corrosion resistance. The concept of Pitting Resistance Equivalent (PRE) was introduced as a practical tool for evaluating resistance to localized corrosion.

Dr. Sussex emphasized that most weld failures arise from poor preparation, contamination, incorrect heat input, and inadequate purging. Issues such as hot cracking, porosity, heat tint formation, zinc contamination, and sigma phase formation were explained in detail, along with their impact on corrosion resistance and mechanical performance. Proper weld joint design, surface cleaning, controlled interpass temperatures, and post-weld treatments like pickling are essential to restore the protective chromium oxide layer. The session also highlighted inspection methods—including visual testing, dye penetrant, radiography, and ultrasonic testing—as key elements of weld quality assurance. Overall, the webinar reinforced that successful stainless steel welding requires technical expertise, strict process control, and adherence to established standards to ensure long-term reliability.

This second part of the Nickel Institute webinar continues with Dr. Graham Sussex providing deeper insights into stainless steel welding practices, focusing on advanced defect prevention, microstructural control, and corrosion-related challenges. The session further emphasizes proper heat input management, purging techniques, contamination control, and post-weld treatments to maintain corrosion resistance and structural integrity. It reinforces the importance of qualified procedures, inspection methods, and adherence to industry standards to ensure durable and high-quality stainless steel welds in demanding service environments.

The webinar panel featured Nimesh Chinoy, Krishnan Sivaraman, Chris Wiseman, Ashok Malage, and James Bell, each contributing expertise from different areas of welding technology and materials engineering. Nimesh Chinoy, representing industry leadership, set the context by highlighting advancements in welding innovation and collaboration. Chris Wiseman shared insights from a materials science perspective, focusing on metallurgical principles, material behavior, and global best practices. James Bell contributed technical depth on modern joining technologies and process optimization, while Krishnan Sivaraman and Ashok Malage provided perspectives related to industrial applications, fabrication challenges, and skill development within the welding sector.

The discussion centered on improving weld quality, understanding material performance under service conditions, and strengthening the link between industry needs and technical standards. Topics included process control, defect prevention, metallurgy-driven decision-making, training and certification, and the importance of adherence to international codes. Together, the panel emphasized knowledge sharing, innovation, and disciplined execution as key drivers for enhancing welding performance and long-term structural reliability across industries.

How Can Advanced Welding Practices Improve Quality and Long-Term Performance?

This webinar explores the critical role of modern welding practices in achieving high-quality, reliable, and durable welded structures. The session discusses how proper material selection, understanding of metallurgical behavior, and strict control of welding parameters directly influence weld integrity and service life. Emphasis is placed on heat input management, microstructural control in the weld metal and heat-affected zone (HAZ), and the importance of selecting suitable consumables to match application requirements.

The discussion also highlights practical industry challenges such as defect prevention, distortion control, contamination management, and adherence to recognized standards. Quality assurance measures—including procedure qualification, inspection techniques, and skilled workforce development—are emphasized as essential components of successful fabrication. Overall, the webinar reinforces that combining technical knowledge with disciplined execution and continuous improvement is key to enhancing welding performance across demanding industrial applications.

The video presents a detailed overview of local vacuum power beam welding, with particular emphasis on electron beam welding (EBW) and its applications in the energy sector. The speaker outlines the limitations of conventional multi-pass welding techniques for thick-section components, highlighting issues such as high energy consumption, extended production times, preheating requirements, and potential defects. In contrast, local vacuum EBW enables single-pass, full-penetration welds with minimal distortion and reduced residual stresses. By generating a controlled vacuum environment only around the weld seam rather than enclosing the entire structure in a large vacuum chamber, the technology overcomes traditional size constraints and allows the welding of large industrial components under ambient workshop conditions.

The presentation further demonstrates the relevance of this technology for offshore wind foundations, nuclear pressure vessels, and emerging applications such as small modular reactors and hydrogen production systems. Industrial case studies confirm high weld quality, regulatory compliance, low shrinkage, and favorable mechanical properties without the extensive consumables and thermal treatments required in conventional processes. The discussion also highlights how reduced-pressure environments enhance laser welding performance by improving penetration depth and minimizing plasma-related defects. Overall, the video underscores local vacuum beam welding as a technically advanced, economically efficient, and strategically significant solution for thick-section fabrication in renewable and nuclear energy infrastructure.

The video provides a comprehensive discussion on advanced joining technologies and manufacturing processes that are critical to the development of electric vehicle (EV) batteries and related high-technology sectors. It highlights the complexity of battery joining due to variations in cell formats and material combinations, which demand precise and reliable joining solutions. Among the available techniques, laser welding and ultrasonic welding are identified as the most mature and widely adopted processes, offering strong mechanical performance, electrical reliability, and suitability for high-volume automated production. The session also emphasizes the importance of quality assurance through mechanical, electrical, and thermal testing methods, while underscoring the growing challenge of battery recycling. The lack of standardized battery designs complicates automated dismantling and resource recovery, making sustainability and circular economy strategies a pressing priority.

In addition to battery technologies, the presentation explores advanced manufacturing methods such as additive manufacturing (AM) and hot isostatic pressing (HIP), which are increasingly supplementing conventional fabrication techniques. These processes enable the production of lightweight, complex, and high-performance components with improved material efficiency and reduced waste, particularly in automotive and aerospace applications. However, qualification, certification, and standardization remain significant barriers to widespread industrial adoption. Overall, the video highlights the essential role of technological innovation, regulatory development, and industry collaboration in achieving scalable, cost-effective, and sustainable solutions for the evolving EV market and other high-value engineering sectors.

This webinar, hosted by the IIW Mumbai Branch with support from the International Molybdenum Association (IMOA) and the Nickel Institute, provides a comprehensive technical overview of weld repair strategies for stainless steels and nickel alloys. It begins by emphasizing nickel’s critical role in over 75% of stainless steel production, highlighting its contribution to durability, corrosion resistance, and long service life across industries such as energy, transportation, infrastructure, and low-carbon technologies. Sustainability is a key theme, with discussion on emission reductions, recyclability of nickel, and its enabling role in renewable energy systems and advanced battery technologies. The session then transitions into practical repair considerations, stressing that successful emergency weld repair depends on proper material identification, assessment of damage type (mechanical vs. corrosion), safety evaluation, adherence to applicable codes (such as ASME PCC-2), and careful decision-making between temporary and permanent solutions. The importance of alloy verification—through documentation, alloy analyzers, and magnetic testing—is highlighted as foundational before any welding begins.

The technical core of the webinar focuses on weldability challenges across stainless steel families (austenitic, duplex, ferritic, martensitic, and precipitation-hardenable) and nickel alloys. Austenitic stainless steels are generally the easiest to repair, but high-temperature exposure can lead to sensitization, sigma phase formation, and embrittlement, particularly in cast alloys with higher carbon content. Duplex steels demand strict heat input and nitrogen control to maintain phase balance, while martensitic and PH grades pose hardness and cracking challenges. Nickel alloys require even greater cleanliness, low heat input, and often overmatching filler metals to prevent cracking and corrosion failures. The speaker emphasizes practical field realities—favoring SMAW over GTAW in less-controlled environments, maintaining low hydrogen conditions, controlling interpass temperatures, and applying butter layers in embrittled materials. Ultimately, the webinar underscores that thorough investigation, surface preparation, filler metal selection, and disciplined welding procedures are critical to ensuring safe, durable repairs—while recognizing that in many severe cases, full component replacement may be more economical and reliable than repeated weld repair.

About the Webinar Speakers: Mr. Pradip Goswami Master’s Degree (Metallurgy-Welding from Indian Institute of Technology, Chennai, India, in 1983. International Welding Engineer (IWE), and Canadian Welding Bureau Certified Professional Welding Engineer– “Welding Procedure & Practices”.

Topics Covered: A.RP 934-A, RP 934-C, RP 934-E  a)Scope b)Base Metal Requirements c)Welding Consumable Requirements d)Welding, Heat Treatment, and Production Testing e)Final Post weld Heat Treatment f)Nondestructive Examinations. g)Hydrostatic Testing h)Documentation i)Summary Material Examination and NDE Requirements

 This webinar will focus on selecting the proper corrosion-resistant alloy for a particular application, highlighting four common mistakes that result in either the wrong alloy being chosen or a suitable alloy not performing adequately. These are based on personal experiences. The ones that will be discussed are: a) Misuse of PREN (Pitting Resistance Equivalent numbers) b) Lack of knowledge of contaminants c) Lack of knowledge of actual equipment operation d) Secrets from fabrication shop. With the knowledge gained, these mistakes will hopefully be avoided in the future About the Webinar Speaker : Mr.Gary Coates P.Eng. Gary is Technical Manager for the Nickel Institute, Toronto, Canada.

About the Webinar Speakers: Mr. Pradip Goswami Master’s Degree (Metallurgy-Welding from Indian Institute of Technology, Chennai, India, in 1983. International Welding Engineer (IWE), and Canadian Welding Bureau Certified Professional Welding Engineer– “Welding Procedure & Practices”. Currently he is working as a Consultant-Welding, Metallurgical & Corrosion Engineering with a major Engineering and Consulting (EPCM) organization in Canada, with current & extensive involvement in Oil & Gas FEED & EPIC Projects.Such experiences are borne out from thorough familiarity with various ASME Codes, NACE, DNV & API standards applicable for both upstream and downstream oil and gas production and refining environment.

About the Webinar Speaker: Mr.Baher Elsheikh, Mechanical engineer, has 20 years of experience in the oil and gas and petrochemical industry, particularly in the engineering, reliability, construction, and troubleshooting of pressure equipment and fired heaters. He worked in refinery, petrochemical, and fertilizer plants as a senior mechanical engineer specializing in static equipment. Baher is a certified RBI professional (API 580) and damage mechanism professional (API 571). He published multiple papers and articles in international journals and conferences.

The workshop is a discussion on Requirements to attain Weld Process, Ownership with Manual / Robot GMA and Gas Shielded Flux Core. About the Webinar Speaker: Ms.Emily Craig Senior Weld Mgr. Weld Engineer,USA She worked as Senior Weld Engineer on putting humans on Mars & completion of the world’s first commercial Tokamak Fusion Reactor projects. Weld Process Expertise. For four plus decades, Em has been an arc Weld Process Controls & Best Weld Practice expert with the world’s most common arc weld processes. GMAW – GTAW – Flux Cored. Hot Wire GTAW – TIP TIG – SAW – & Plasma welding. Between contract consult and full-time positions, Em. provided “hands on”, manual, automated and robot welding quality and productivity improvements and training programs for hundreds of companies in 13 countries.

This webinar will consider these issues, how to measure galvanic effects, and apply control measures when breaking the metal-to-metal connection is not possible. Basic electrochemical measurements can be used to estimate effects in complicated combinations of seals and alloy combinations. Multiple examples will be supplied including advice on the difference between stray current and galvanic corrosion.   About the Webinar Speaker: Dr. Graham Sussex worked as a materials and corrosion consultant in the UK and Australia for more than 35 years. Since 2001 a major part of his work has been as Technical Specialist for the Australian Stainless Steel Development Association answering technical enquiries and resolving problems – many related to welding. Since 2014, he has done similar work for the Nickel Institute. Graham is an active contributor to Australian and ASTM standards development much related to stainless steels and welding.

This webinar session provides a highly practical and experience-driven discussion on the welding and repair of P91 creep-resistant steel, emphasizing that it is not just another low alloy material but a highly sensitive martensitic steel requiring strict procedural discipline. The speaker highlights the metallurgical fundamentals behind P91, particularly martensitic transformation, AC1 temperature control, and the critical importance of post-weld cooling before PWHT. Key insights include the need to control nickel and manganese levels, limit heat input, maintain proper interpass temperatures, and use step bevel configurations to minimize Type IV cracking in the heat-affected zone. The discussion makes it clear that improper PWHT, excessive heat input, or deviation from controlled procedures can drastically reduce creep life and lead to premature failure.

Through technical explanations and real industrial case studies, the session reinforces that most P91 failures stem from fabrication errors, poor design configurations, or inadequate heat treatment control rather than inherent material weakness. The importance of qualified personnel, proper supervision during PWHT, and strict adherence to approved welding procedures is strongly emphasized. Overall, the webinar delivers a valuable technical reminder that successful P91 welding demands metallurgical understanding, controlled heat treatment practices, and disciplined field execution to ensure long-term reliability in high-temperature service applications.

How Can We Weld Duplex Stainless Steel Without Compromising Its Performance?

This session explains that successful duplex stainless steel welding depends on maintaining the balance between ferrite and austenite phases, which directly affects strength and corrosion resistance. The speaker emphasizes controlling heat input, cooling rate, and interpass temperature, along with selecting filler metals rich in nickel and using nitrogen in shielding gas to compensate for nitrogen loss during welding. Proper ferrite control—not necessarily achieving an exact 50–50 ratio—is key to maintaining mechanical integrity and pitting resistance.

The webinar also highlights real-world corrosion risks such as pitting and crevice corrosion, explaining how poor welding practices, arc strikes, spatter, or surface oxidation can reduce service life. By linking PREN values to practical corrosion performance and stressing strict process control, the session reinforces that duplex welding requires metallurgical understanding, disciplined parameter control, and careful execution to ensure long-term reliability in aggressive environments.

This Weld Tech Talk session, organized by IIW Mumbai, featured an engaging and practical presentation by Ms. Bailey Cameron, following an introduction by Dr. Krishnan and a company overview by Mr. Nilesh Chincholkar of Sigma Welding. Ms. Bailey Cameron presented a comprehensive discussion on successful production welding, covering WPS, PQR, and WPQ fundamentals, welding process selection, heat input control, heat treatment requirements, and real-world field challenges. She emphasized that welding success depends not only on qualified procedures and codes but also on proper planning, service awareness, welder competency, location constraints, and effective communication among teams. The session reinforced that a practical, application-focused approach is essential to prevent failures and ensure long-term reliability in industrial welding operations.

This webinar began with a brief introduction from the sponsor, Electronic Devices Pvt. Ltd., showcasing Sigma’s welding and heating technologies used across automotive, packaging, healthcare, and industrial applications. The session was supported by the Nickel Institute and IMOA, with Jürg, Market Development Manager (Southeast Asia) at the Nickel Institute, introducing the organizations and their mission to promote the proper use of nickel and alloy systems. He then introduced the keynote speaker, Gary Coates, Technical Manager at the Nickel Institute, with over 48 years of experience in stainless steel and nickel alloy metallurgy.

Gary’s technical session focused on practical welding aspects of austenitic, ferritic, and martensitic stainless steels. He highlighted common misconceptions in filler metal selection, the importance of ferrite control to prevent hot cracking, distortion management, and the need for proper material identification. The discussion emphasized that stainless steel welding is not just about passing qualification tests, but about understanding metallurgy, corrosion environments, and service conditions to ensure long-term performance and reliability.

How Can Duplex and Super Duplex Stainless Steels Be Welded Successfully?

This webinar explained that welding duplex and super duplex stainless steels requires strict control of heat input, interpass temperature, and cooling rate to maintain the critical ferrite–austenite balance. The speaker emphasized that excessive heat can cause harmful intermetallic phases like sigma phase, while rapid cooling can lead to high ferrite and reduced toughness. Proper filler metal selection, nitrogen control in shielding and purge gases, and oxygen management are essential to preserve corrosion resistance, particularly in demanding environments such as desalination and offshore systems.

The session also highlighted practical issues such as arc strikes, surface contamination, improper pickling, and the importance of ferrite measurement and corrosion testing standards. Real-world examples showed how poor welding practices can result in cracking or severe corrosion. Overall, the key takeaway was that duplex welding is metallurgically sensitive and demands disciplined heat control, correct consumables, and careful surface finishing to ensure long-term reliability.

This IIW Mumbai webinar, supported by the Nickel Institute, focused on the corrosion behavior and welding of copper–nickel (90/10, 70/30) and nickel–copper (Alloy 400, K500) alloys. The session highlighted their strong performance in marine environments due to copper ion release that reduces biofouling, while also explaining how stagnant conditions and improper cathodic protection can reduce this benefit. The differences between solid-solution copper–nickel alloys and precipitation-hardened K500 were also clarified in terms of strength and service performance.

On the welding side, the speaker emphasized that high nickel content reduces weld penetration and increases weld pool viscosity, requiring lower heat input, strict cleanliness, controlled interpass temperature, and proper filler metal selection. Special attention was given to dilution control and buttering techniques in dissimilar welds to prevent hot cracking and contamination. Overall, the key message was that successful welding of these alloys depends on metallurgical understanding and disciplined process control to ensure long-term reliability in marine and refinery service.

How Can Ferrous and Non-Ferrous Cladding Be Applied Effectively in Industrial Applications?

This webinar explained that both ferrous (stainless steels, carbon steels, duplex steels) and non-ferrous (nickel alloys, copper-nickel alloys, and other CRA materials) cladding are used to combine strength, corrosion resistance, and cost efficiency in demanding industries. Ferrous cladding is commonly applied using stainless steel overlays on carbon steel to enhance corrosion resistance while maintaining structural strength. In contrast, non-ferrous cladding—particularly nickel-based alloys such as Alloy 625—is selected for severe environments involving high temperatures, sour service, or aggressive chemical exposure. The speaker emphasized that dilution control, filler metal compatibility, and multi-layer deposition are critical to ensuring the final surface chemistry meets design requirements.

The session also highlighted key differences between ferrous and non-ferrous systems, including ferrite control in austenitic stainless steels, the risk of martensitic formation at the interface, and the sensitivity of nickel alloys to high heat input and cracking. Process selection—such as submerged arc, GTAW, or strip cladding—must balance deposition rate and dilution control. Overall, the key takeaway was that successful ferrous and non-ferrous cladding requires metallurgical awareness, strict heat input management, and thorough inspection to guarantee long-term mechanical integrity and corrosion performance.