What is Weld Overlay?

Weld Overlay is a process that utilizes welding to apply one or more layers of a special alloy to the surface of a base material. Weld overlay not only significantly reduces costs compared to traditional monolithic alloy fabrication, but also provides equipment with both “solid substrate strength” and “superior surface performance”.

 

Common Problems of Glass Molds

There are various common problems of glass molds in the process of using, including:

1. Wear and Scratch

The contact friction between the glass and the surface of the mold at high temperature leads to the wear and tear of the surface of the mold; 

2. Thermal cracks and deformation

Thermal stress concentration caused by high temperature alternation and localized cooling; 

3. Chemical corrosion and adhesion

Glass at high temperature or chemical composition (e.g. alkaline glass) is easy to react with metal surface;

resulting in adhesion, scratches or peeling off of the mold surface.

4. Dimensional accuracy degradation

Wear and thermal deformation reduce the accuracy of the mold, affecting the quality of molded products.

 

Through welding cladding technology, these failure problems can be solved effectively and the service life of the mold can be extended significantly.

 

Advantages of Weld Overlay Glass Molds

The main missions of Weld Overlay on glass molds are as follows:

Performance enhancements

•  Enhanced abrasion resistance

•  Corrosion resistance

•  Erosion / impact resistance

•  High temperature or thermal fatigue resistance

Repair and Restore Dimensions

When equipment or components experience dimensional reduction or deviation due to wear, corrosion, heat treatment deformation, or other factors, Weld Overlay can restore them to their original dimensions or near-original condition.

Extend Service Life / Reduce Maintenance Costs

The overlay significantly slows component degradation under harsh operating conditions, thereby reducing replacement frequency and downtime.

Cost Savings

Compared to manufacturing entire components from high-performance materials, applying surface overlays is often substantially less expensive while preserving the structural strength and rigidity of the base material.

 

Differences Between Weld Overlay, Cladding, and Hardfacing

Within the industry, Weld Overlay, Cladding, and Hardfacing are often used interchangeably or confused, yet they possess distinct differences:

Hardfacing

Specifically refers to coatings applied for wear resistance, impact resistance, or abrasion resistance, typically emphasizing hardness and wear performance. It represents one functional approach within Weld Overlay.

Cladding

Primarily focuses on forming protective layers, often prioritizing corrosion resistance, isolation, or erosion resistance. Cladding can be applied via welding (e.g., Weld Overlay Cladding) or mechanically (e.g., rolling, explosive bonding). The cladding material typically differs from the base material.

Distinguishing Overlap (Weld Overlay) from Cladding

Weld Overlay: Involves fusing an alloy or material onto the substrate via welding; emphasizes metallurgical bonding and welding process.

Cladding: Broadly encompasses welding, mechanical bonding, or other joining methods; primarily aims to protect or cover the substrate.

 

In certain applications or manufacturer terminology, “weld overlay cladding” may refer to a coating that is both a cladding and a weld overlay.

 

How to Obtain Welding Overlay Services?

If you have a preferred company, you can contact them regarding your welding overlay requirements. You may send them an email, call their hotline, or reach out to their customer service for assistance. Shanghai Duomu Industrial Co., Ltd., as a leading enterprise in the welding overlay service industry, is an excellent choice. Contact us! Learn about welding overlay processes or customize professional welding overlay solutions tailored to your needs.