Automated weld overlay services
Advanced corrosion protection solutions
Extend the operational lifecycle of your mission-critical assets with Sulzer’s CladFuse™ precision cladding technology. Our advanced Weld Overlay solutions deliver industry-leading corrosion protection and high-performance coatings, using high speed, automated processes designed to minimize downtime during critical turnarounds.
High-performance corrosion mitigation for static equipment
In aggressive industrial environments, conventional base materials are subject to progressive wear and corrosion over time. Our CladFuse™ Weld Overlay process applies a fully bonded, corrosion resistant alloy layer that restores the structural integrity of your equipment and enhances its corrosion resistance. Unlike surface coatings or temporary repair methods, this automated cladding produces a permanent metallurgical bond with controlled dilution and consistent overlay quality. Engineered for demanding service conditions, it delivers proven performance in high-pressure, high-temperature environments, providing superior erosion-corrosion protection and extending asset service life.
Core applications:
- Weld Overlay for Pressure Equipment: Total internal protection for Pressure Vessels including Coke Drums, Distillation Units, Reactors, Columns, Digesters and more.
- Weld Overlay for Boilers: Specialized protection solutions against the high-temperature corrosion and erosion in industrial boilers found in Power Generation, Waste-to-Energy (WtE) and Biomass facilities. We inspect, repair and upgrade boiler tubes and waterwalls.
Technical excellence in surface engineering
To ensure the highest quality of corrosion protection solutions, Sulzer adheres to rigorous engineering standards throughout the repair and protection cycle.
- Qualified welders: All our procedures and welders are qualified under international codes (ASME, AWS) to guarantee safety and compliance on every project.
- Minimal dilution & HAZ control: Our automated systems precisely controls weld parameters, heat input, minimizing dilution and the Heat Affected Zone (HAZ).
- Engineered Alloy Weld Overlay: Qualified WPS and application expertise enable precise alloy selection for each corrosion and erosion mechanism.
- GMAW / GTAW automated cladding: We utilize advanced Gas Metal Arc Welding and Gas Tungsten Arc Welding processes — GMAW GTAW cladding — to ensure precision, repeatability, and consistency across every application.
Why integrate weld overlay into your maintenance strategy?
Choosing automated weld overlay services is a proactive step in static equipment maintenance. By applying a specialized cladding layer before significant metal loss occurs, you:
- Reduce total cost of ownership: Extend asset life and avoid the massive capital expenditure of replacing entire vessels.
- Enhance reliability: A fully fused metallurgical bond eliminates the risk of coating delamination.
- Minimize equipment downtime: Our High-speed Automated systems are essential for fast-track turnaround services, getting your plant back online sooner.