Overlay Welding: Extending the Life and Strength of Industrial Equipment
- Madden Fabrication
- Nov 21
- 5 min read
Imagine a $500,000 drill grinding to a halt, not because of a broken motor, but because of a worn-down surface that is costly to repair. If you’re in heavy industry, you understand how expensive equipment and downtime can be, and avoiding these issues should be a top priority.
That is why overlay welding isn’t just a smart option — it is a game changer.
In this article, we will discuss how welding overlay works, how its applications extend equipment life in various industries, and the top benefits of overlay welding. With this information in hand, you can make the best fabrication decision for your business without compromising on durability or quality.
Table of Contents
What Is Welding Overlay?
Welding overlay is a process where a layer of material is welded onto the surface of a base material to improve its properties and restore its dimensions. This technique is used to enhance the wear of a component without having to replace it entirely. It is often used to:
Rebuild worn parts and valves.
Create corrosion-proof lining for pipelines and pressure valves.
Add abrasion-resistant coating.
Overlay Welding vs. Traditional Welding
Although overlay welding and traditional welding involve joining materials through heat, they serve different purposes and are used in various contexts.
One of the main differences between the two is that overlay welding focuses on protecting the product rather than on durability or joining materials.
Cladding vs. Weld Overlay
When it comes to weld overlay vs cladding, understanding the differences can be challenging because the terms are often used interchangeably, but there are subtle differences between them. While both involve adding a protective layer to the base material, their methods, materials, and applications can vary.
Cladding usually involves bonding a corrosion-resistant metal layer, while weld overlay is a welding-based process where molten material is applied to the metal surface to improve:
Wear resistance
Corrosion protection
The life of a component
The Weld Overlay Process
Step 1 – Surface Preparation
Surface preparation is a critical first step of the weld overlay process. Proper preparation ensures strong adhesion between the base material and the overlay. This can minimize the risk of cracking or lack of fusion. You can do this by:
Cleaning
Surface roughening
Inspection
Preheating (not always necessary)
Step 2 – Welding Application
After the surface is prepared correctly, you can proceed with the welding application using an overlay welding machine. This involves depositing a layer of filler material onto the base metal using a suitable welding method. Some welding techniques include:
Gas Metal Arc Welding (GMAW/MIG): Uses a wire electrode and shielding gas. It is commonly used for large surfaces with minimal downtime.
Gas Tungsten Arc Welding (GTAW/TIG): Used for high-quality overlays with minimal dilution. This method is known for its welding precision and control.
Submerged Arc Welding (SAW): This method is known for its ability to create thick overlays and is used in industrial and heavy-duty applications.
Plasma Transferred Arc (PTA): Delivers a dense, high-quality overlay that is usually used in high-wear conditions
Laser Cladding: This method uses a focused laser beam to melt and bond the overlay to the base metal. It provides excellent control, low dilution, and extended component life.
Step 3 – Finishing and Inspection
After the overlay is applied, the component is inspected to ensure quality and integrity. This can involve:
Visual inspections for surface defects
Non-destructive testing (NDT), which can include ultrasonic or radiographic testing strategies
Finish operations such as grinding to achieve the final surface finish and size
At Madden Fabrication, our team of professionals has been performing overlay welding for various industries for over 30 years. We understand how to prepare, choose the proper welding application, and finish the product meeting proper inspection requirements. If you are unsure how overlay welding can be used in your business, contact our team today, and we can help.
3 Applications of Overlay Welding Across Industries
#1: Protecting Heavy Equipment Components
Overlay welding can extend the lifespan of valves, rollers, and shafts in high-wear environments by reinforcing and protecting these high-wear parts. This benefit is especially valuable in construction, mining, agriculture, and harsh conditions.
#2: Enhancing Corrosion Resistance in Chemical and Marine Settings
In specific industries, corrosion resistance is imperative to ensuring products do not rust. In chemical and marine settings, for example, this can be particularly important. Stainless or nickel alloys are applied to enhance durability and safety without the high cost of corrosion-resistant materials. These products can be an excellent option for pipelines, tanks, and marine parts.
#3: Restoring and Rebuilding Industrial Machinery
Overlay welding is widely used to repair and rebuild worn-out machine components. Instead of replacing expensive machines and equipment, damaged surfaces are restored by applying wear-resistant layers. For example, refurbishing products like pump shafts or cooling rods can cost 20-25% less than new parts and can be completed in a few weeks rather than months. Reducing the cost and downtime may save millions for companies in replacements.
Benefits of Overlay Weldingel
Overlay welding offers a cost-effective and reliable solution for advancing the durability and performance of essential components in various industries. It can be particularly beneficial by:
Extended equipment life
Saving money
Improved performance
Versatility across various materials and industries
Customizable protection
Reduced downtime
Environmental benefits
At Madden Fabrication, we know how beneficial overlay welding can be, and the cost-saving qualities can be a game-changer when it comes to efficiency and reducing downtime. If you are considering using overlay welding for your components but have questions, our team can help. We provide a variety of fabrication services and education to support our clients with their fabrication needs. Contact us today to get started.
Choosing the Right Fabrication Partner for Overlay Welding
It is essential to find the right fabrication partner for your overlay welding needs to ensure your components are properly fabricated. You want to look for welders who:
Are highly skilled in overlay welding techniques
Use advanced equipment
Have proven experience with similar projects
Follow strict quality control procedures to ensure consistency and performance
Madden Fabrication checks all of these blocks with their reliable and experienced team, capable of executing projects ranging from overlay welding to custom lighting. Contact us today to see how we can provide fabrication support for your company.
Count on Madden Fabrication for Expert Overlay Welding Services
If you need overlay welding services for your next fabrication project, look no further than Madden Fabrication. With over 30 years of experience, we have been able to provide high-quality metal fabrication services in the Portland area and beyond.
In addition to overlay welding, we also provide many other fabrication services to ensure your fabrication needs are met, such as:
Structured steel fabrication
Aluminum fabrication
Custom steel fabrication
Custom stainless steel fabrication
Custom nickel alloy fabrication
Custom alloy fabrication
Facility maintenance
We also serve the fabrication needs of a variety of industries, including:
Commercial contractors
Historical restoration
OEM industry
Oil and gas
Power plants
Renewable energy
Agricultural industry
Waste treatment
Food processing
Hospitality
Chemical plants
And more.
Contact our team today to get started on your next fabrication project.