Duplex Welding Training & Consultancy

🛠️ What is Specialized Welding Training & Consultancy?

Specialized welding refers to advanced techniques used for welding high-performance, corrosion-resistant materials such as Titanium, Nickel alloys, Inconel, and Duplex stainless steel. These materials are often used in extreme conditions, including high temperatures, aggressive environments, and high-stress applications in industries like aerospace, marine, power generation, and chemical processing.

Our Welding Training & Consultancy Services offer:

• Expert welding techniques for challenging alloys
• Process optimization for specific material properties
• High-quality weld performance and defect prevention
• Industry-standard certifications for welders and procedures

🌟 Materials We Specialize In

1️⃣ Titanium Welding

• Properties of Titanium: Lightweight, high strength, excellent corrosion resistance, especially in extreme temperatures.
• Applications: Aerospace, medical implants, chemical processing, marine (subsea).

Challenges in Welding Titanium:

• Sensitive to contamination: Needs inert gas shielding (e.g., argon).
• Sensitive to heat: High temperatures can affect material properties.
• Requires precise control of welding parameters (voltage, amperage, shielding gas flow).

Training Focus:

• TIG (Gas Tungsten Arc Welding) techniques for titanium alloys.
• Contamination control and cleanliness practices.
• Welding parameters: Heat control, preheat, and post-weld heat treatment.

2️⃣ Nickel Alloys Welding

• Properties of Nickel Alloys: Excellent resistance to oxidation, corrosion, and high-temperature environments.
• Applications: Gas turbines, heat exchangers, nuclear reactors, aerospace components.

Challenges in Welding Nickel Alloys:

• Tendency to form cracks: Requires special welding procedures and filler materials.
• Heat and thermal expansion: Can lead to distortion or cracking.

Training Focus:

• Weld process selection: Choosing between TIG, MIG, or SMAW based on alloy type.
• Pre-heating and post-weld heat treatment to avoid cracking.
• Control of intergranular corrosion by managing the cooling rate.

3️⃣ Inconel Welding

• Properties of Inconel (e.g., Inconel 625, 718): High strength, oxidation, and corrosion resistance in extreme temperatures.
• Applications: Aircraft engines, chemical processing plants, power plants, nuclear reactors.

Challenges in Welding Inconel:

• High sensitivity to heat: Requires precise heat input control.
• Cracking susceptibility: Especially in the heat-affected zone (HAZ).

Training Focus:

• Welding methods: TIG, MIG, and submerged arc welding.
• Welding parameter control to avoid cracking and deformation.
• Post-weld heat treatment (PWHT) for stress relief.
• Selection of appropriate filler materials for strength and corrosion resistance.

4️⃣ Duplex Stainless Steel Welding

• Properties of Duplex Steel: Combination of austenitic and ferritic microstructures, offering high strength, excellent resistance to stress corrosion cracking, and superior pitting resistance.
• Applications: Chemical processing, marine environments, offshore oil rigs, paper and pulp industry.

Challenges in Welding Duplex Steel:

• Maintaining balance between ferrite and austenite phases.
• Avoiding carbide precipitation which can compromise corrosion resistance.
• Need for precise heat input control to avoid phase imbalance.

Training Focus:

• Welding methods: Mostly TIG and MIG processes.
• Maintaining ferrite content in the weld to avoid cracking and reduce stress corrosion.
• Post-weld heat treatment (PWHT) to stabilize phases and avoid brittleness.
• Filler material selection for optimal corrosion resistance.

🎓 Training & Certification Services

1. Tailored Welding Training Programs

• Customized Courses: Tailored to your team’s specific needs and the materials they’ll be working with.
• Hands-on Training: Real-world scenarios to practice on Titanium, Nickel alloys, Inconel, and Duplex stainless steel.
• Level I & II Training: For beginners to intermediate welders, covering the fundamental principles and applications.
• Advanced Welding Techniques: For senior welders and welding supervisors to manage complex welds and challenging materials.

2. Welder Qualification & Certification

• WPQ (Welder Performance Qualification): Certification in compliance with international standards (ASME, AWS, ISO).
• WPS/PQR Assistance: Development and qualification of Welding Procedure Specifications and Procedure Qualification Records.

3. Welding Procedure Development

• Creation of WPS for complex materials (Titanium, Inconel, etc.) ensuring compliance with applicable codes.
• Development of PQR based on material specifications, welding parameters, and heat treatment.

🛠️ Consultancy Services Offered

1. Process Optimization

• Welding Procedure Review and Optimization: Evaluation of existing procedures and making recommendations for improving efficiency, reducing costs, and improving weld quality.
• Automation Integration: Introducing robotic welding and automation to enhance productivity and precision.

2. Failure Analysis & Root Cause Investigation

• Identifying reasons for welding failures such as cracks, porosity, and corrosion.
• Metallurgical analysis and corrective actions to prevent future issues.

3. Equipment Selection & Setup

• Guidance on the best equipment and technology for welding Titanium, Nickel alloys, Inconel, and Duplex steel.
• Assistance with parameter selection for optimal performance and cost-effectiveness.

4. Quality Control & Assurance

• Implementation of quality management systems for welding, ensuring compliance with ISO, AWS, ASME, and other standards.
• NDT (Non-Destructive Testing) services to verify weld quality and integrity.

5. On-Site Supervision

• Providing welding supervisors on-site to ensure proper techniques are being followed, and assist in resolving any challenges faced during welding operations.

💡 Why Choose Our Welding Training & Consultancy?

• Expert Trainers: Industry-certified professionals with decades of experience working with Titanium, Nickel, Inconel, and Duplex steels.
• Global Standards: Training and consultancy aligned with international welding standards such as ASME, AWS, ISO, and more.
• Customized Programs: We design programs specifically for the challenges and materials your team is working with.
• Quality Assurance: Ensure optimal performance and compliance with code requirements and client specifications.
• Competitive Advantage: Having a highly qualified team skilled in welding these advanced alloys helps your company stand out in the marketplace.

📈 Benefits for Businesses

• Increased productivity and efficiency through optimized welding processes.
• Enhanced weld quality, reducing the risk of failure and rework.
• Minimized downtime and operational delays due to faulty welding procedures.
• Improved safety by ensuring welders are trained to handle complex and high-risk materials safely.
• Enhanced competitiveness in the marketplace by offering specialized welding services.