Product Description
Endless Torch Rotation Overlay Clad Bore Cladding System
Weld overlay, or cladding, involves covering the 'wetted' surfaces of a workpiece (those exposed to hostile media) with a protective layer, usually of stainless steel or nickel-based alloy.
The use of TIG welding in this clad welding process has certain advantages:
1) The accuracy of the process when welding overlay complex surfaces, especially when welding overlay zones with corners, curves or inside or outside edges, avoids the need for manual touch-ups.
2) The separate control of arc energy and the quantity of metal deposited is advantageous when cladding tricky geometries.
3) Welding energy transferred to the workpiece is controlled, optimising the ratio of welding energy-to-deposition rate according to workpiece typology.
4) The welding sequences can be interrupted and resumed at any time, avoiding microcracks and craters at the start and end of beads.
FITco is honored to provide model XHL-ETR cladding station which is designed for heavy and complex shaped products for oil & gas, chemical, valve manufacturing, pressure vessels and other industries, the welding torch is designed as endless rotation which can meet the requirements of a wide range of different shape products.
Fitco can specially design and produce the tig welding equipments
according to clents' requirements.
Heavy and complex component welding is always a huge challenge. This is where the advantages of the FITco ETR system come into
play, thanks to intelligent Fitco i-CLAD 300 control system, this model features multiple holes and standard welding of components of different
angles and sizes. The automatic alignment function significantly reduces the time required to manually find centers for traditional heavy
components
With compact design, this model is space-saving and powerful. Configured with the basic functions of internal and external surface together with flat surface welding, this mode also boasts optional functions such as two holes 90-degree crossing intersection surface cladding, multi-bore intersection surface automatic welding, workpiece pre-heat system, workpiece cooling system, etc.
Our pipe cladding equipment features advanced quad-head technology that enhances deposition rates while minimising heat input to the base metal. This results in lower Fe% dilution and higher welding travel speeds, ensuring efficiency and quality.
Technical Parameter
| 1 |
Type of Power Source |
DC Type Inverter |
| 2 |
Welder Current
Duty Circle (40ºC) |
5~450A
450A 80%; 420A 100A |
| 3 |
Hot Wre Current
Duty Cycle (40ºC) |
5~200A
200A 60%; 100A 100% |
| 4 |
Open Circuit Voltage |
80V |
| 5 |
Input Voltage |
3×400V (-25%+20%) 50/60Hz |
| 6 |
Input Power |
35KVA |
| 7 |
AVC Accuracy |
±0.2V |
| 8 |
Recommend Peak Current |
150~280A |
| 1 |
Welding Process |
Automatic TIG Hot Wire |
| 2 |
Inverter Cooling |
Air Cooling |
| 3 |
Displayer |
5.7"screen Chinese/English displayer
Real-time parameter displayer |
| 4 |
Fault Detect |
Work piece short circuit, over temperature protection, over current protection, over voltage protection, water shortage protection, lack of gas protection, power error, arc failure, servo error. |
| 5 |
Overlay Processing |
Dia.: φ30 (after cladding) - φ2500mm
Max height for vertical overlay: ≤2500mm
Loading bearing 10 tons |
| 6 |
Wire Dia |
1.2/1.6mm (1.0mm Optional) |
| 7 |
Tungsten Dia. |
3.2mm (4.0mm optional) |
| 8 |
Torch Cooling |
External Constant Temperature Circulating Water Cooling |
| 9 |
ARC Starting |
HF/Contact |
| 10 |
Power Source |
EWM TETRIX 452DC Ethernet/IP HF Unit |
| 11 |
Hot Wire Power |
EWM TETRIX 200 Hot Wire Power |
| 12 |
Single Layer |
1-3mm |
| 13 |
Gas Flow Rate |
12-20L/min |
1.This model is compact design, saving space and powerful.
Internal and external bore, flat surface cladding and two holes 90-degree cross-section cladding are standard functions.
2. We also provide multiple 90-degree cross-hole section, sphere borehole, multi-position one-time automatic cladding, workpiece pre-heating system, workpiece air cooling system and other optional functions, specifically according to the commercial contract options to determine the cladding function block of the whole machine.
- Complete Turnkey System
- System Controller with Touch-Screen Control
- Germany EWM TETRIX 452 DC Ethernet/IP HF-TIG Unit Power Source
- Germany EWM TETRIX 200 Smart Hot Wire Power Source
- Controller: Rockwell AB USA
- Servo Motor: ICON MOONS
- Electrical Switch & Button: Famous brand
- HMI: Pro-face Japan
- Control Panel & Structure: Fitco, China
- Rotation Table: Fitco, China
- Limit Switch: Sick, Germany
Applications:
- Base material: A105, A350 LF2, A694 F42~F70, AISI 4130, 30CrMo, SS304/304L, SS316/316L, SS410, F51, F55, WCB, LCB casting, forged materials or pipe base materials;
- Weld Consumables: ERNiCrMo-3, ERNiFeCr-1, ER316L, ER2594, ERCCoCr-E, ERCCoCr-A, ERNi1, ERCuNi and other wires;
- Clad thickness: 1~3mm/layer, multilayer cladding, standard clad thickness will be 3.2mm, FL+2mm dilution will be less than 5%;
- Quality requirements: Liquid Penetrant Testing as per ASTM E165 & ASTM V requirements. First time yield for intersection surface cladding will be >95%, bore or flat surface cladding >98%, ring groove cladding >96%.
- Welding process: Automatic TIG hotwire;
- Welding Position: 2G or 1G typically.
Weld overlay cladding is essential for critical oil and gas equipment such as Xmas trees, subsea and topside manifolds, induction bends, tees, reducers, and connector hubs.
Programs
We provide automatic surface cladding, automatic inner hole cladding, intersection cladding as a standard function. Below you can find more functions by select different program options. All below red, green and pink color area can be weld overlaid full automatically. Which will bring best quality and lower human labor to our valued customer.
Application Products
Pipe rings, Fittings, Flanges, LR bends, Valve Bodies, Valve Balls, Risers, Well head block tree valves, Pressure Vessel Components, Nozzle, Dished ends, etc.
Utilizing advanced automated welding equipment our machine can repair corroded or eroded areas by building back the worn area, restoring to an acceptable thickness and applying an upgraded metallurgy to reduce future issues.
Weld overlay technology enhances component lifespan and cost efficiency by applying a protective layer that resists corrosion, wear, and erosion. This extends operational life of assets, reducing the need for frequent replacements while minimising downtime and maintenance costs. With our expertise in weld cladding and advanced materials, we deliver high-quality, reliable solutions that provide long-term value.
Advantage
Advantages:
Fitco originated and grew up in manufacturing plants that use our equipment to produce products, so we understand the needs of our products, processes and operators better than other equipment manufacturers Fitco is from China's largest and the world's leading welding products manufacturing plant. Our equipment is more stable and intelligent with higher customer recognition; We use the world's top programmable controller platform and mathematical models to program our devices more intelligently!
FITCO Performance
After Sales Service
Guarantee period and after-sales service:
- After-sales technical services and spare parts supply is supplier's responsibility;
- Supplier shall implement quality assurance on the product under normal conditions of use, and from the date of the final acceptance signature, Supplier shall guarantee the equipment for 12 months (except for consumables and man-made damage). During the warranty period, the quality of the supplier's equipment itself is indeed the supplier responsible for free maintenance, if the equipment failure caused by improper use, the supplier should send technicians to solve the problem in a timely manner, Customer is responsible for a reasonable cost. "The use of non-genuine parts and substitutes is considered an automatic waiver of warranty rights.
- "After the expiration of the warranty, Supplier will carry out life-long maintenance of their products.
- During the quality assurance period, when the equipment failure in the process of use of the equipment is not resolved, Party B in the notice within 8 hours to respond, such as Customer still cannot troubleshoot, Supplier within 2 week to send maintenance engineers.
- After the warranty period of the equipment, provide a wide range of preferential technical support for life.
Company Profile
Our Company--Faith-Han Intelligent Technology Co., Ltd.
Founded and registered in 2018, Fitco is located in Kunshan High-tech District, between Shanghai and Suzhou.
Fitco is committed to designing and manufacturing non-standard customized automation control intelligent industrial welding/welding equipment, manufacturing information software, auxiliary equipment and related products and services.
Fitco has designed and manufactured more than 150 sets of welding equipment for the Chinese and the international market. Our equipment is highly stable and intelligent that has been proven on-site for many years, gaining the respect of our global customers and markets. The extensive use of mathematical models in our programs makes our machines more intelligent than our competitors' products. Environmental friendliness and safety are always our top priority when it comes to mechanical and electrical design.
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