What is Cladding and When to Use it

The materials that resist corrosion in specific applications may lack adequate structural strength. Alternatively, their low strength could necessitate the use of uneconomically thick sections. A cost-effective solution involves applying a layer of corrosion-resistant material of appropriate thickness to the contact surfaces of equipment made from a structurally strong material, such as carbon steel. This technique, which combines two different material layers, is known as Cladding or Lining.

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While "Lining" refers to various types of materials, "Cladding" specifically denotes a metallic corrosion-resistant layer that is well-bonded to the surface. Consequently, the term Cladding is commonly used for steel-fabricated equipment, such as pressure vessels and shell and tube heat exchangers.

It is essential to note that the structural strength is provided solely by the base material. Aside from corrosion, the cladding must endure prevailing temperatures, stresses, and potential abrasion. Cladding presents a cost-effective alternative by delivering a relatively thin corrosion barrier made of a costly corrosion-resistant metal or alloy, paired with an inexpensive, structurally strong base material that can handle all load conditions.

There are multiple methods for attaching a corrosion-resistant metal or alloy layer to the base metal. Cladding involves joining two sheets: the base material, which resists all loads, and the corrosion-resistant material, which is either welded or fused using various techniques. Another technique, Weld Overlay, includes welding (either manually or automatically) corrosion-resistant metal onto the base metal. In both scenarios, the outcome is the same: a strong and economical base material that withstands the load, along with a thin layer of corrosion-resistant metal serving as a protective barrier. These methods can be employed individually or in combination.

A general guideline for considering cladding is as follows: If vessels require a thickness of 75-85 mm (or more) to endure operating conditions, constructing the entire vessel from a corrosion-resistant alloy may be excessively expensive. A 3 mm layer of corrosion-resistant alloy cladded onto a 75-85 mm steel plate could significantly reduce costs while providing equivalent corrosion resistance. However, cladding is not always the most efficient technical or economic choice. The fabrication of cladded vessels is often complex and costly. Furthermore, thermal cycling can lead to issues at the weld points of sleeves and nozzles. Cracks or corrosion may also arise at the welds where adjacent sheets are joined in clad-metal construction.

The economic evaluation of clad versus corrosion-resistant solid base materials hinges on several factors: the unit cost of specific materials, their relative fabrication costs, and the complexity of the equipment. There are no universal rules for selecting one alternative over the other; each case must be independently assessed.

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If you wish to know more:

• ASME VIII | Design of Pressure Vessels
• TEMA | Design of Shell & Tube Heat Exchangers
• Piping Systems in Industrial Plants: I

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