{"id":42576,"date":"2025-01-13T10:03:37","date_gmt":"2025-01-13T09:03:37","guid":{"rendered":"https:\/\/www.kremsmueller.com\/news\/first-application-of-electroslag-welding-for-major-order\/"},"modified":"2025-05-05T10:06:36","modified_gmt":"2025-05-05T08:06:36","slug":"first-application-of-electroslag-welding-for-major-order","status":"publish","type":"post","link":"https:\/\/www.kremsmueller.com\/en\/news\/first-application-of-electroslag-welding-for-major-order\/","title":{"rendered":"First application of Electroslag Welding for major order"},"content":{"rendered":"\t\t
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Application of Electroslag Welding for large order<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Kremsmueller has manufactured and delivered equipment for a customer in the petrochemical industry using the ESW (Electroslag Welding) process.<\/strong><\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\t\t\t\t\tA key requirement was to apply a stainless steel coating to the flanges and the inside of the jacket of the components for corrosion protection. \u201cDuring the planning phase, it turned out that ESW was the best solution due to its cost efficiency, as it costs around three times less,\u201d says project manager Alois W. This process has been part of Kremsmueller’s service portfolio for around 10 years and has now been successfully applied for the first time in these dimensions.

Electroslag strip cladding (ESW): What is it and how does it work?<\/strong>
ESW is a special submerged arc welding process. \u201cThe process is used to increase the durability or service life of a component,\u201d explains Daniel I., Head of the Welding and Testing Technology Department. ESW enables a protective layer to be applied to a carrier material quickly and efficiently. The base material is usually cheaper than the high-alloy protective coating. The alternative would be to manufacture the component entirely from the high-alloy material. \u201cHowever, this variant would cost many times more,\u201d says the welding expert.
In electroslag strip cladding, a strip material, usually made of stainless steel or nickel alloy, and a special powder mixture are melted using an electric arc and applied to the workpiece. The slag acts as a heat source and shielding gas.

Procedure for the apparatus<\/strong>
The major challenge, in addition to selecting the right strip\/flux combination, was to determine the correct welding parameters and component shrinkage due to the high heat input. Different welding samples were also created for the three devices in order to determine the optimum parameters. Flanges, for example, were deliberately made larger in order to compensate for the shrinkage caused by welding.

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From tests to qualification<\/strong>
\u201cThe path to qualification of the ESW process involved several steps to ensure safe and correct application,\u201d explains the welding expert. The welders underwent special training that included both theoretical and practical content. After the training, they had to take a certification test in the presence of T\u00dcV to confirm their knowledge and skills.<\/p>\n

To qualify the welding process, test pieces were welded and then subjected to a comprehensive destructive test. The fulfillment of the mechanical\/technological values and corrosion resistance were confirmed by the T\u00dcV.
After welding, various non-destructive testing procedures such as visual inspection, surface crack testing, ultrasonic testing and PMI testing (Positive Material Identification) are required. \u201cThese tests ensure that the weld seams meet the required quality standards,\u201d explains Daniel I.<\/p>\n

Advantages and application examples of ESW<\/strong>
ESW offers cost advantages, a high deposition rate and low mixing with the base material, which makes it attractive for numerous industrial applications. With strip cladding, layers of 3 to 5 mm can be applied with only 15 to 20 % mixing. This means that the desired chemical composition of the surface can often be achieved after just one or two layers.
One example of the use of ESW, as with our equipment, is in the petrochemical industry, where it is used to improve the corrosion protection of pressure vessels.
ESW is also used in the oil and gas industry, for example to protect valves and pumps against wear.<\/p>\n

Limitations of ESW<\/strong>
Despite its many advantages, ESW also has some limitations, such as material compatibility, the thickness of the cladding and geometric limits. These factors should be taken into account when planning and implementing ESW projects in order to achieve the best possible results.<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t

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Application of Electroslag Welding for large order Kremsmueller has manufactured<\/p>\n","protected":false},"author":8,"featured_media":31888,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[112,87,92],"tags":[],"class_list":["post-42576","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-company-group","category-petrochemicals","category-special-weldig-parts"],"acf":[],"_links":{"self":[{"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/posts\/42576","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/users\/8"}],"replies":[{"embeddable":true,"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/comments?post=42576"}],"version-history":[{"count":3,"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/posts\/42576\/revisions"}],"predecessor-version":[{"id":42579,"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/posts\/42576\/revisions\/42579"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/media\/31888"}],"wp:attachment":[{"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/media?parent=42576"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/categories?post=42576"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.kremsmueller.com\/en\/wp-json\/wp\/v2\/tags?post=42576"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}