| Abstract Scope |
High deposition robotic gas metal arc cladding (GMAC) processes are needed for cladding complex shapes used in advanced energy and chemical systems. This project developed cold wire assisted (CWA) tandem (T) GMAC process relationships for nickel (Ni), nickel-copper (Ni-Cu), and copper-nickel (Cu-Ni). clad materials. Tests were performed to evaluate the effects of cold wire position feed relative to tandem gas metal arcs on pool stability and cladding performance. The goal was to develop process relationships that enabled uniform underbead, controlled dilution under 6%, and maximum deposition rate on curved features as small as 6-inch diameter.
Cladding parameter optimization began on flat plates before transitioning to round mockups. The tests were used to simulate the range of curved surface features from large diameter (i.e. flat plate) to small diameter that would be difficult to clad using flux based cladding processes. Once robust cladding procedures were established, comprehensive evaluations were conducted to evaluate bond integrity. These included inspections for bond uniformity, porosity levels, clad composition, and ductility. Successful procedures were then employed to fabricate ring clad on small diameter pipe at maximum deposition rate that met all quality criteria.
Results demonstrated that the developed CWA-TGMAC process met all quality. Clad tests exhibited uniform bonding, acceptable composition, and successfully passed destructive tests including turn down to evaluate bond uniformity and bend testing. Notably, the process achieved a 28-lb/hr. deposition rate on small 6-inch diameter features.
In conclusion, the project successfully developed and validated advanced cladding procedures for Ni, Ni-Cu, and Cu-Ni cladding on small diameter features. The optimized CWA-TGMAC process offers both high-quality deposition, good uniform bond profile, and improved productivity compared to single or tandem GMA process alternatives. These results indicate strong potential for widespread adoption of this process for robotic cladding next generation energy and chemical process equipment.
**Pending Distro A** |