CermaClad- Metallurgically Bonded Overlays for Oil and Gas

Oil sands processing involves transporting highly abrasive slurries in corrosive environments, and a chief operating cost is the repair and replacement of worn components and pipe.  Traditionally, laser, PTA. and MIG weld overlay of chrome carbide and tungsten carbide have been used to combat wear, along with the use of rubber linings and wear tiles.    Each of these processes is relatively slow or expensive.  CermaClad™ WRA is a wear resistant overlay applied using high rate fusion cladding processes utilizing a unique, high density infrared arc as the heating source.  This process produces significantly improved metallurgy compared to weld overlay processes, and is 10-100X faster in application rates, reducing costs and boosting productivity dramatically compared to conventional weld overlay and PTA processes.  More specifically, CermaClad can apply smooth, crack-free,, decarburization-free, and undiluted carbide coatings to thicknesses exceeding 10mm, very rapidly in 10” wide scans, being able to clad a 45’ pipe in under 2 hours, compared to many days for conventional processes.  This paper will present the high rate fusion overlay process, present data and examples of microstructures and abrasion performances produced using the technology.  Status and availability of high rate fusion cladding services in the oil sands marketplace will also be discussed.