Zhuojin Pipe Fitting Co., LtdApplication of ESAB Strip Electrode Surfacing Technology
Literature Overview
This article, published in Electrician Welder (2013, Vol. 43, Issue 5, pp. I0014-I0017), provides an overview of the application of ESAB strip electrode surfacing technology across various industrial sectors. The article covers submerged arc strip electrode surfacing and strip electrode electroslag welding, highlighting their advantages in terms of high deposition rates and low dilution rates for large-scale surfacing operations on pressure vessels, heat exchanger tube sheets, hydroelectric turbine blades, mining equipment, and pressure vessels.
Process Comparison: SAW vs. ESW Strip Electrode Surfacing
The article draws a clear distinction between submerged arc welding (SAW) strip electrode surfacing and electroslag welding (ESW) strip electrode surfacing. While both processes use strip electrodes to achieve high deposition rates, they differ fundamentally in their melting mechanisms and applicable geometries:
| Feature | SAW Strip Electrode | ESW Strip Electrode |
|---|---|---|
| Melting mechanism | Arc melting | Slag pool melting |
| Deposition rate | High (3–5× single wire SAW) | Very high (5–10× single wire SAW) |
| Dilution rate | Moderate (5–15%) | Low (2–8%) |
| Geometry | Flat or slightly curved | Flat or gently curved |
| Layer thickness | 3–8 mm per pass | 5–15 mm per pass |
| Heat input | Moderate | High |
| Cooling rate | Moderate | Low |
| Typical application | Boiler drums, vessel shells | Large flat surfaces, thick sections |
Application Domains
The article identifies several key application areas where strip electrode surfacing technology delivers significant advantages:
- Pressure vessel and heat exchanger internals: Corrosion-resistant overlay layers on tube sheets and vessel linings where high deposition rates reduce production time.
- Hydroelectric turbine blades: Wear-resistant overlay on blade surfaces exposed to abrasive water flow.
- Mining and construction equipment: Hardfacing of bucket teeth, dozer blades, and other wear-critical components.
- Nuclear power components: Low-dilution overlay layers on reactor internals and containment components.
Engineering Considerations
For large-scale production surfacing, the selection between SAW and ESW strip electrode processes depends on several factors. When dilution rate control is critical, as in nuclear applications or when overlaying dissimilar metals, ESW is preferred because the electroslag process produces lower dilution rates. When the substrate geometry includes significant curvature, SAW strip electrode surfacing is more adaptable. In high-volume production environments, ESW can reduce cycle time by 40 to 60 percent compared to conventional single-wire SAW, making it economically attractive for large flat or gently curved surfaces.
Study Insights
This article serves as a practical guide for engineers evaluating strip electrode surfacing technology for large-scale industrial applications. The key insight is that the choice between SAW and ESW strip electrode processes should be driven by a systematic assessment of dilution rate requirements, substrate geometry, production volume, and economic factors. For engineers working in the power generation, chemical processing, or heavy equipment sectors, this technology represents a significant productivity improvement over conventional surfacing methods, provided that the process parameters are properly optimized for the specific application.